Portable power case with heat-resistant material

ABSTRACT

Systems, methods, and articles for a portable power case are disclosed. The portable power case is comprised of at least one battery and at least one PCB. The portable power case has at least two access ports, at least two leads, or at least one access port and at least one lead and at least one USB port. The portable power case is operable to supply power to an amplifier, a radio, a wearable battery, a mobile phone, and a tablet. The portable power case is operable to be charged using solar panels, vehicle batteries, AC adapters, non-rechargeable batteries, and generators. The portable power case provides for modularity that allows the user to disassemble and selectively remove the batteries installed within the portable power case housing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to and claims priority from the following USpatent applications: this application is continuation of U.S.application Ser. No. 15/836,299, filed Dec. 8, 2017, which is acontinuation-in-part of U.S. application Ser. No. 15/664,776, filed Jul.31, 2017, and a continuation-in-part of U.S. application Ser. No.15/720,270, filed Sep. 29, 2017. U.S. application Ser. No. 15/664,776 isa continuation-in-part of U.S. application Ser. No. 15/470,382, filedMar. 27, 2017, which is a continuation-in-part of U.S. application Ser.No. 14/516,127, filed Oct. 16, 2014. U.S. application Ser. No.15/720,270 is a continuation-in-part of U.S. application Ser. No.14/520,821, filed Oct. 22, 2014, and a continuation-in-part of U.S.application Ser. No. 15/664,776, filed Jul. 31, 2017, which is acontinuation-in-part of U.S. application Ser. No. 15/470,382, filed Mar.27, 2017, which is a continuation-in-part of U.S. application Ser. No.14/516,127, filed Oct. 16, 2014. Each of the U.S. Applications mentionedabove is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to a portable power casecomprised of at least one battery that allows the user to disassembleand selectively remove the batteries installed within the portable powercase housing.

2. Description of the Prior Art

The military uses various types of portable electronic devices, such asportable battery-operated radios, which generate heat during operation,i.e., during normal operation, the devices may be heat-generatingdevices. In particular, a malfunctioning device can cause excessiveheating. A drawback of heat-generating devices is that the heat may betransferred to the person using or carrying the device, causinguncomfortableness or burns. Another drawback of heat-generating devicesis that the heat may be transferred to other devices, causing damage tothese devices. Further, in military applications, heat-generatingdevices may increase the heat profile of military personnel, making themmore prone to detection by thermal imaging and therefore more prone todanger.

It is known in the prior art to provide heat dissipating material orinsulating material with heat-generating devices. It is also known inthe prior art to provide a portable power supply for electronic devices,including military radios.

Representative prior art patent documents include the following:

U.S. Pat. No. 5,522,943 for portable power supply by inventors Spenceret al., filed Dec. 5, 1994 and issued Jun. 4, 1996, is directed to aportable power supply that includes at least one solar panel assemblythat is capable of producing an electrical output through the conversionof solar energy to electrical energy. The power supply further includespower transmission means which is typically an electrical cable thatwill supply the power output of the solar panel to an electrical energyconsuming device such as a portable computer or a battery for usetherewith. The portable power supply further includes a case having atleast two opposing side panels and includes solar panel assemblyattachment means permitting the mounting of a solar panel assembly. Thesolar panel assembly typically comprises a photovoltaic panel attachedto a backing panel. Backing panels utilized in the solar panel assemblymay also be foldable, thus protecting the attached photovoltaic panelwithin the folded sections of the backing panel.

U.S. Pat. No. 5,621,299 for rechargeable power supply with load voltagesensing, selectable output voltage and a wrist rest by inventor Krall,filed Nov. 14, 1994 and issued Apr. 15, 1997, is directed to a pluralityof rechargeable batteries are provided as part of an electronic systemthat includes an electronic circuit which controls periodic charging ofthe batteries and allows selection of the output voltage over a givenrange. The system is preferably packaged in a shape to be easilyintegrated with a carrying case, such as a briefcase, and/or tophysically match a specific type of portable equipment, such as anotebook computer. In one embodiment, the batteries and circuitry areincluded in a wrist rest structure of a type used with portable computerkeyboards. In other forms, the power supply is useable with a largenumber of other specific items of portable electronic equipment, such asportable video and telecommunications equipment.

U.S. Pat. No. 7,733,658 for integrated power supply and platform formilitary radio by inventors Perkins et al., filed May 15, 2007 andissued Jun. 8, 2010, is directed to a power platform assembly providedto convert available AC power into power suitable to power SINCGARSradio components. The platform includes a horizontal base for supportingup to two SINCGARS radios and a carriage assembly supported above thebase to provide support for up to two radio frequency power amplifiers.Connectors, internal wiring, and electrical components inside theplatform provide power and electrical connections between componentswithin and connected to the platform. Ancillary electronics andconnectors provide for remote audio monitoring of communications via anLS-671 external speaker, or equivalent external speaker arrangement. Theplatform allows various types of available AC power, as may vary acrossdifferent regions of the world, to power the radios and radio frequencypower amplifiers while allowing others in a secure vicinity of theplatform to hear incoming and outgoing voice transmissions withoutdraining the batteries powering the radios.

U.S. Pat. No. 8,059,412 for integrated power supply and platform formilitary radio by inventors Perkins et al., filed Jan. 26, 2009 andissued November 2011, is directed to an improved power supply andplatform for a military radio. The apparatus includes a base that isadapted and arranged for supporting a HARRIS 117 radio and a poweramplifier adapted to amplify radio frequency output of the radio. Theconnectors include an electrical connector for the radio and a connectorfor the amplifier. A power supply is housed within the assembly. A powersupply for the connector to the amplifier is also housed within theassembly. Also included is a wiring harness for a SINCGARS LS/671 deviceand a LED indicator to identify which radio is in operation for multipleradio configurations.

U.S. Pat. No. 8,149,592 for sealed power supply and platform formilitary radio by inventors Perkins et al., filed Jun. 15, 2010 andissued Apr. 3, 2012, is directed to an AC/DC power supply and platformfor a military radio. The apparatus includes a base that supports atleast one SINCGARS RT-1523 radio. The base is connected to an AC powersupply and at least one DC power supply. The AC supply and DC powersupply are configured to switch automatically to the DC power supplyshould the AC power supply fail. The housing of the platform is sealedfrom the exterior environment with gaskets.

U.S. Pat. No. 8,462,491 for platform for military radio with vehicleadapter amplifier by inventors Perkins et al., filed Mar. 31, 2011, andissued Jun. 11, 2013, is directed to a platform for a military radiowith a vehicle adapter amplifier. The apparatus includes a base forsupporting at least one SINCGARS RT-1523 radio. The platform has a firstpower supply that includes a DC power converter for converting 110/220alternating current into +28 Volt direct current and a second powersupply that converts +28 Volt direct current into +6.75 Volts directcurrent, +13 Volts direct current and +200 Volt direct current. Theplatform includes a vehicle adapter power amplifier that provides rangeextension to said SINCGARS RT-1523 radio.

U.S. Pat. No. 8,531,846 for integrated AC/DC power supply and platformfor military radio by inventors Perkins et al., filed Jun. 7, 2010 andissued Sep. 10, 2013, is directed to an AC/DC power supply and platformfor a military radio. The apparatus includes a base that supports atleast one SINCGARS RT-1523 radio. The base is connected to an AC powersupply and at least one DC power supply. The AC supply and DC powersupply are configured to switch automatically to the DC power supplyshould the AC power supply fail.

U.S. Pat. No. 8,638,011 for portable power manager operating methods byinventors Robinson et al., filed Jun. 15, 2010 and issued Jan. 28, 2014,is directed to various aspects of invention providing portable powermanager operating methods. One aspect of the invention provides a methodfor operating a power manager having a plurality of device ports forconnecting with external power devices and a power bus for connectingwith each device port. The method includes: disconnecting each deviceport from the power bus when no external power device is connected tothe device port; accessing information from newly connected externalpower devices; determining if the newly connected external power devicescan be connected to the power bus without power conversion; if not,determining if the newly connected external power devices can beconnected to the power bus over an available power converter; and if so,configuring the available power converter for suitable power conversion.

U.S. Pat. No. 8,885,354 for mount platform for multiple military radiosby inventors Perkins et al., filed Mar. 15, 2013 and issued Nov. 11,2014, is directed to a platform for a military radio with a vehicleadapter amplifier. The apparatus includes a base for supporting dualAN/VRC-110 radio systems. The platform has a first power supply thatincludes a DC power converter for converting 110/220 alternating currentinto +28 Volt direct current and a second power supply that converts +28Volt direct current into +6.75 Volts direct current, +13 Volts directcurrent and +200 Volt direct current. The platform includes a vehicleadapter power amplifier that provides range extension to said dualAN/VRC-110 radio systems.

SUMMARY OF THE INVENTION

The present invention relates generally to a portable power caseincluding at least one battery that allows the user to disassemble andselectively remove the batteries installed within the portable powercase housing.

In one embodiment, the present invention provides systems, methods, andarticles for a portable power case including at least one rechargeablebattery and a printed circuit board (PCB) disposed within an openinterior space of a hard case or housing. The hard case includes a lidand a base. The portable power case includes at least one universalserial bus (USB) port and at least two access ports, at least two leads,or at least one access port and at least one lead connected to the PCBand accessibly positioned on an exterior surface of the hard case. Theat least one rechargeable battery is selectively removable from the hardcase. The at least one USB port and the at least two access ports, theat least two leads, or the at least one access port and the at least onelead are operable to supply power to at least one electronic device. Theat least two access ports, the at least two leads, or the at least oneaccess port and the at least one lead are operable to charge theportable power case using at least one charging device.

In another embodiment, the present invention provides systems, methods,and articles for a portable power case including at least onerechargeable battery and a printed circuit board (PCB) disposed withinan open interior space of a hard case or housing. The hard case includesa lid and a base. The portable power case includes at least two accessports, at least two leads, or at least one access port and at least onelead connected to the PCB and accessibly positioned on an exteriorsurface of the hard case. The at least one rechargeable battery isselectively removable from the hard case. The at least two access ports,the at least two leads, or the at least one access port and the at leastone lead are operable to supply power to at least one electronic device.The at least two access ports, the at least two leads, or the at leastone access port and the at least one lead are operable to charge theportable power case using at least one charging device. One of the atleast one charging device is a vehicle battery. The portable power caseis connected to the vehicle battery through a cable with a batteryprotector. The battery protector prevents the portable power case fromdraining the vehicle battery.

In yet another embodiment, the present invention provides systems,methods, and articles for a portable power case including at least onerechargeable battery and a printed circuit board (PCB) disposed withinan open interior space of a hard case or housing. The hard case includesa lid and a base. The portable power case includes at least two accessports, at least two leads, or at least one access port and at least onelead connected to the PCB and accessibly positioned on an exteriorsurface of the hard case. The at least one rechargeable battery isselectively removable from the hard case. The at least two access ports,the at least two leads, or the at least one access port and the at leastone lead are operable to supply power to at least one electronic device.The at least two access ports, the at least two leads, or the at leastone access port and the at least one lead are operable to charge theportable power case using at least one charging device. The PCB includescontrol electronics configured to determine a state of charge of theportable power case and/or the at least one electronic device.

These and other aspects of the present invention will become apparent tothose skilled in the art after a reading of the following description ofthe preferred embodiment when considered with the drawings, as theysupport the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a cross-sectional view of one embodiment ofstructures that include material for dissipating heat from electronicdevices and/or clothing.

FIG. 1B illustrates a cross-sectional view of another embodiment ofstructures that include material for dissipating heat from electronicdevices and/or clothing.

FIG. 1C illustrates a cross-sectional view of yet another embodiment ofstructures that include material for dissipating heat from electronicdevices and/or clothing.

FIG. 1D illustrates a cross-sectional view of yet another embodiment ofstructures that include material for dissipating heat from electronicdevices and/or clothing.

FIG. 2A is a view of a radio holder article held in a pouch.

FIG. 2B is a view of the radio holder article of FIG. 2A removed fromthe pouch.

FIG. 3 is a perspective view of an example of a flexible solar panel.

FIG. 4 is an exploded view of an example of a flexible solar panel.

FIG. 5 is a perspective view of an example of a portable battery pack.

FIG. 6 is another perspective view of an example of a portable batterypack.

FIG. 7 is yet another perspective view of an example of a portablebattery pack.

FIG. 8 is a perspective view of an example of a wearable pouch of aportable battery pack.

FIG. 9 is another perspective view of an example of a wearable pouch ofa portable battery pack.

FIG. 10 is yet another perspective view of an example of a wearablepouch of a portable battery pack.

FIG. 11A illustrates a front perspective view of the wearable pouch orskin of the portable battery pack.

FIG. 11B illustrates a side perspective view of the wearable pouch orskin of the portable battery pack.

FIG. 11C illustrates a back perspective view of the wearable pouch orskin of the portable battery pack.

FIG. 11D illustrates a perspective view of an end of the wearable pouchor skin of the portable battery pack.

FIG. 11E illustrates a perspective view of another end of the wearablepouch or skin of the portable battery pack.

FIG. 12A illustrates an exploded view of an example of a battery of aportable battery pack.

FIG. 12B illustrates an exploded view of an example of a battery of aportable battery pack into which the heat dissipating material isinstalled.

FIG. 13 is a perspective view of a battery of a portable battery pack.

FIG. 14 is another perspective view of a battery of a portable batterypack.

FIG. 15 illustrates an exploded view of an example of a battery intowhich the heat dissipating material is installed.

FIG. 16 illustrates a view of an example of a battery base.

FIG. 17 illustrates another view of an example of a battery base.

FIG. 18A illustrates a top perspective view of the battery lid.

FIG. 18B illustrates a cross-section view of the battery lid.

FIG. 18C illustrates a side perspective view of the battery lid.

FIG. 18D illustrates another cross-section view of the battery lid.

FIG. 19A illustrates a top perspective view of the battery base.

FIG. 19B illustrates a cross-section view of the battery base.

FIG. 19C illustrates a detail view of a part of the cross-section viewof the battery base shown in FIG. 19B.

FIG. 19D illustrates a side perspective view of the battery base.

FIG. 19E illustrates another cross-section view of the battery base.

FIG. 19F illustrates another side perspective view of the battery base.

FIG. 20 illustrates a view of a BA-5590 female connector.

FIG. 21 illustrates a block diagram of a portable power case into whichthe heat dissipating material is installed.

FIG. 22 illustrates a block diagram showing the inside of one embodimentof the portable power case.

FIG. 23 illustrates a block diagram of the connections to the printedcircuit board (PCB).

FIG. 24 illustrates a block diagram of one embodiment of the controlelectronics for a state of charge indicator incorporated into theportable power case.

FIG. 25A illustrates a block diagram of an example of an SOC system thatincludes a mobile application for use with a portable power case.

FIG. 25B illustrates a block diagram of an example of controlelectronics of the portable power case that is capable of communicatingwith the SOC mobile application.

FIG. 25C illustrates a block diagram of another example of controlelectronics of the portable power case that is capable of communicatingwith the SOC mobile application.

FIG. 26A illustrates an angled perspective view of a rechargeablebattery in a housing for mating with a PRC-117F radio.

FIG. 26B illustrates a top view of a rechargeable battery in a housingfor mating with a PRC-117F radio.

FIG. 26C illustrates a side view of a rechargeable battery in a housingfor mating with a PRC-117F radio including a connector.

FIG. 26D illustrates another side view of a rechargeable battery in ahousing for mating with a PRC-117F radio.

FIG. 27A illustrates a view of the exterior of one embodiment of theportable power case.

FIG. 27B illustrates a view of the exterior of another embodiment of theportable power case.

FIG. 28 illustrates a view of the portable power case showing the USBports.

FIG. 29 illustrates one example of the portable power case lined withmaterial resistant to heat.

FIG. 30A illustrates one embodiment of the access ports of the portablepower case.

FIG. 30B illustrates a keyway of the access ports of the portable powercase.

FIG. 30C shows a view of one embodiment of a portable power case withleads.

FIG. 30D shows a cutaway view of one embodiment of a portion of theportable power case showing more details of the leads.

FIG. 31 illustrates a block diagram of a portable power case in an ATVwith three passengers.

FIG. 32 illustrates a block diagram of a portable power case in an ATVwith four passengers.

FIG. 33A illustrates an angled view of the housing of one embodiment ofa DC-DC converter cable.

FIG. 33B illustrates an end view of the housing of one embodiment of aDC-DC converter cable.

FIG. 33C illustrates a side view of the housing of one embodiment of aDC-DC converter cable.

FIG. 33D illustrates a cross-section of the housing of one embodiment ofa DC-DC converter cable.

FIG. 33E illustrates an end view of a connector end cap for the housingof one embodiment of a DC-DC converter cable.

FIG. 33F illustrates an angled view of a connector end cap for thehousing of one embodiment of a DC-DC converter cable.

FIG. 33G illustrates an end view of a grommet end cap for the housing ofone embodiment of a DC-DC converter cable.

FIG. 33H illustrates an angled view of a grommet end cap for the housingof one embodiment of a DC-DC converter cable.

FIG. 34 illustrates a block diagram of the battery protector.

FIG. 35 illustrates a portion of a combination signal marker panel andsolar panel.

FIG. 36 illustrates a front perspective view of a combination signalmarker panel and solar panel while folded.

FIG. 37 illustrates a back perspective view of one embodiment of acombination signal marker panel and solar panel while folded.

FIG. 38 illustrates a top perspective view of one embodiment of thecombination signal marker panel and solar panel while unfolded.

FIG. 39 illustrates another portion of a combination signal marker andsolar panel.

FIG. 40 illustrates one embodiment of a signal marker panel.

FIG. 41 illustrates another embodiment of a signal marker panel.

DETAILED DESCRIPTION

The present invention is generally directed to a portable power casecomprised of at least one battery that allows the user to disassembleand selectively remove the batteries installed within the portable powercase housing.

In one embodiment, the present invention provides systems, methods, andarticles for a portable power case including at least one rechargeablebattery and a printed circuit board (PCB) disposed within an openinterior space of a hard case or housing. The hard case includes a lidand a base. The portable power case includes at least one universalserial bus (USB) port and at least two access ports, at least two leads,or at least one access port and at least one lead connected to the PCBand accessibly positioned on an exterior surface of the hard case. Theat least one rechargeable battery is selectively removable from the hardcase. The at least one USB port and the at least two access ports, theat least two leads, or the at least one access port and the at least onelead are operable to supply power to at least one electronic device. Theat least two access ports, the at least two leads, or the at least oneaccess port and the at least one lead are operable to charge theportable power case using at least one charging device.

In another embodiment, the present invention provides systems, methods,and articles for a portable power case including at least onerechargeable battery and a printed circuit board (PCB) disposed withinan open interior space of a hard case. The hard case includes a lid anda base. The portable power case includes at least two access ports, atleast two leads, or at least one access port and at least one leadconnected to the PCB and accessibly positioned an exterior surface ofthe hard case. The at least one rechargeable battery is selectivelyremovable from the hard case. The at least two access ports, the atleast two leads, or the at least one access port and the at least onelead are operable to supply power to at least one electronic device. Theat least two access ports, the at least two leads, or the at least oneaccess port and the at least one lead are operable to charge theportable power case using at least one charging device. One of the atleast one charging device is a vehicle battery. The portable power caseis connected to the vehicle battery through a cable with a batteryprotector. The battery protector prevents the portable power case fromdraining the vehicle battery.

In yet another embodiment, the present invention provides systems,methods, and articles for a portable power case including at least onerechargeable battery and a printed circuit board (PCB) disposed withinan open interior space of a hard case. The hard case includes a lid anda base. The portable power case includes at least two access ports, atleast two leads, or at least one access port and at least one leadconnected to the PCB and accessibly positioned on an exterior surface ofthe hard case. The at least one rechargeable battery is selectivelyremovable from the hard case. The at least two access ports, the atleast two leads, or the at least one access port and the at least onelead are operable to supply power to at least one electronic device. Theat least two access ports, the at least two leads, or the at least oneaccess port and the at least one lead are operable to charge theportable power case using at least one charging device. The PCB includescontrol electronics configured to determine a state of charge of theportable power case and/or the at least one electronic device.

In other embodiments, the present invention provides systems, methods,and articles for a portable power case having a heat-shielding orblocking and/or heat-dissipating material layer or coating. Theheat-shielding or blocking and/or heat-dissipating material is used toprevent and/or minimize heat transfer and the thermal effects producedfrom batteries, as well as to prevent and/or minimize heat transfer fromexternal heat-producing articles or objects.

Team operations in remote locations, such as military operations,require radios to allow team members to communicate about danger,injuries, opportunities, etc. Without radios in these environments, morepeople would be injured or die. These operations also require otherequipment (e.g., amplifiers, wearable batteries, mobile phones, tablets)to allow team members to communicate, survey the environment, etc. Theradios and other equipment typically require lithium ion batteries.However, the lithium ion batteries may not be able to the power theradios and other equipment for the time necessary to complete theoperation on a single charge. As such, a portable power supply may berequired to recharge the lithium ion batteries.

Additionally, the team operation may be attacked by enemy forces,requiring the team to quickly escape. Further, shipping large lithiumion batteries or devices with lithium ion batteries is banned or highlyregulated in most parts of the world due to the risk of overheatingand/or fire. What is needed is a portable power case that allows a userto disassemble and selectively remove the batteries installed within theportable power case housing. As lithium ion batteries were developed inthe 1970s and have been in commercial use since the 1990s, there is along-felt unmet need for a portable power case that is operable tosupply power to at least one electronic device, is operable to becharged using at least one charging device, and allows the user todisassemble and selectively remove the batteries installed within theportable power case housing.

None of the prior art provides a portable power case that is operable tosupply power to at least one electronic device, is operable to becharged using at least one charging device, and allows the user todisassemble and selectively remove the batteries installed within theportable power case housing.

Certain aspects of the presently disclosed subject matter of theinvention, having been stated hereinabove, are addressed in whole or inpart by the presently disclosed subject matter, and other aspects willbecome evident as the description proceeds when taken in connection withthe accompanying illustrative examples and figures as best describedherein below.

Referring now to the drawings in general, the illustrations are for thepurpose of describing a preferred embodiment of the invention and arenot intended to limit the invention thereto.

The present invention provides a material for 1) reducing or eliminatingheat exposure from external objects or other heat-producing devicesand/or 2) dissipating heat from at least one battery or heat-producingelectronic device. The heat blocking or shielding and/orheat-dissipating material is incorporated into the housing of aheat-producing device or battery pack housing, or any article ofclothing or fabric. In one example, a heat shielding or blocking and/orheat-dissipating material layer is sandwiched between two substrates,wherein the substrates may be flexible, rigid, or a combination of bothflexible and rigid.

When applied to clothing, the heat blocking or shielding and/orheat-dissipating material is operable to protect a person's skin fromburns from a heat-generating article or source. Surprisingly, oneembodiment of the heat blocking or shielding and/or heat-dissipatingmaterial layer was discovered when it was in a person's hand but theywere not burned by a heat gun when holding the material in hand, betweenthe heat gun and skin. It was later tested and proved completelyheat-resistant, heat-shielding, and/or heat-dissipating up totemperatures of heat guns (up to about 1,000 degrees Fahrenheit),propane torches (up to about 3,623 degrees Fahrenheit), and oxygen-fedtorches (up to about 5,110 degrees Fahrenheit). These surprising testresults combined with other trials generated the embodiments of thepresent invention and the particular examples that are described herein,in particular for linings or coatings that are constructed andconfigured especially for heat blocking or shielding and/orheat-dissipating material layer or coating applied to objects forprotecting an article from any external heat source, as well asdissipating heat produced by heat-producing devices and their batteries.

FIG. 1A and FIG. 1B are cross-sectional views of examples of structuresthat include the material for dissipating heat from electronic devicesand/or clothing. The heat-dissipating material can be used incombination with, for example, one or two substrates. For example, FIG.1A shows a structure 100 that includes a heat-dissipating layer 120. Theheat-dissipating layer 120 can be sandwiched between a first substrate125 and a second substrate 130.

The heat-dissipating layer 120 can be any material that is suitable fordissipating heat from electronic devices and/or clothing. Theheat-dissipating layer 120 can be from about 20 μm thick to about 350 μmthick in one example. In particular embodiments, the heat-dissipatinglayer 120 can have a thickness ranging from about 1 mil to about 6 mil,including, but not limited to, 1, 2, 3, 4, 5, and 6 mil, or about 25 μmto about 150 μm, including, but not limited to, 25, 50, 75, 100, 125,and 150 μm. Examples of the heat-dissipating layer 120 includeanti-static, anti-radio frequency (RF), and/or anti-electromagneticinterference (EMI) materials, such as copper shielding plastic or copperparticles bonded in a polymer matrix, as well as anti-tarnish andanti-corrosion materials. A specific example of the heat-dissipatinglayer 120 is the anti-corrosive material used in Corrosion InterceptPouches, catalog number 034-2024-10, available from University ProductsInc. (Holyoke, Mass.). The anti-corrosive material is described in U.S.Pat. No. 4,944,916 to Franey, which is incorporated by reference hereinin its entirety. Such materials can comprise copper shielded or copperimpregnated polymers including, but not limited to, polyethylene,low-density polyethylene, high-density polyethylene, polypropylene, andpolystyrene. In another embodiment, the heat shielding or blockingand/or heat-dissipating layer is a polymer with aluminum and/or copperparticles incorporated therein. In particular, the surface area of thepolymer with aluminum and/or copper particles incorporated thereinpreferably includes a large percent by area of copper and/or aluminum.By way of example and not limitation, the surface area of theheat-dissipating layer includes about 25% by area copper and/oraluminum, 50% by area copper and/or aluminum, 75% by area copper and/oraluminum, or 90% by area copper and/or aluminum. In one embodiment, theheat shielding or blocking and/or heat-dissipating layer issubstantially smooth and not bumpy. In another embodiment, the heatshielding or blocking and/or heat-dissipating layer is not flat butincludes folds and/or bumps to increase the surface area of the layer.Alternatively, the heat-shielding or blocking and/or heat-dissipatinglayer 120 includes a fabric having at least one metal incorporatedtherein or thereon. The fabric further includes a synthetic component,such as by way of example and not limitation, a nylon, a polyester, oran acetate component. Preferably, the at least one metal is selectedfrom the group consisting of copper, nickel, aluminum, gold, silver,tin, zinc, or tungsten.

The first substrate 125 and the second substrate 130 can be any flexibleor rigid substrate material. An example of a flexible substrate is anytype of fabric. Examples of rigid substrates include, but are notlimited to, glass, plastic, and metal. A rigid substrate may be, forexample, the housing of any device. In one example, both the firstsubstrate 125 and the second substrate 130 are flexible substrates. Inanother example, both the first substrate 125 and the second substrate130 are rigid substrates. In yet another example, the first substrate125 is a flexible substrate and the second substrate 130 is a rigidsubstrate. In still another example, the first substrate 125 is a rigidsubstrate and the second substrate 130 is a flexible substrate. Further,the first substrate 125 and the second substrate 130 can be single-layeror multi-layer structures.

In structure 100 of FIG. 1A, the heat-shielding or blocking and/orheat-dissipating layer 120, the first substrate 125, and the secondsubstrate 130 are bonded or otherwise attached together, by way ofexample and not limitation, by adhesive, laminating, stitching, orhook-and-loop fastener system. In another example and referring now toFIG. 1B, in a structure 105, the first substrate 125 is bonded to oneside of the heat shielding or blocking and/or heat-dissipating layer120, whereas the second substrate 130 is not bonded or otherwiseattached to the other side of the heat shielding or blocking and/orheat-dissipating layer 120. In yet another example and referring now toFIG. 1C, in a structure 110, the first substrate 125 is provided looselyagainst one side of the heat shielding or blocking and/orheat-dissipating layer 120 and the second substrate 130 is providedloosely against the other side of the heat-dissipating layer 120. Thefirst substrate 125 and the second substrate 130 are not bonded orotherwise attached to the heat shielding or blocking and/orheat-dissipating layer 120. In still another example and referring nowto FIG. 1D, in a structure 115, the heat shielding or blocking and/orheat-dissipating layer 120 is provided in combination with the firstsubstrate 125 only, either bonded or loosely arranged. In FIG. 1D, ifthe two layers are loosely arranged, the heat-dissipating layer 120 isnot bonded or otherwise attached to the first substrate 125. Thepresently disclosed material is not limited to the structures 100, 105,110, 115. These structures are exemplary only.

The heat-shielding or blocking and/or heat-dissipating layer 120 can beused as a protective shield against heated objects and also for reducingthe heat profile of objects. For example, in military applications, theheat shielding or blocking and/or heat-dissipating layer 120 can be usedto reduce the heat profile of devices or clothing for military personnelto reduce the risk of their being detected by thermal imaging.

Other examples of applications and/or uses of the heat-shielding orblocking and/or heat-dissipating layer 120 include, but are not limitedto, insulating battery packs, for example in any battery housing orelectronic device housing; protecting device and/or users fromundesirable external heat; forming sandwich structures; form fitting toa particular device; enclosing electronic materials to prevent corrosionor feathering; medical applications to protect patients from heateddevices used in surgical procedures, for example, in robotics (e.g., foruse in disposable, sterile drapes); forming solar panels; lining tents(e.g., to prevent heat from going in or out); forming heat shields orguards for mufflers on, for example, motorcycles, lawn mowers, leafblowers, or weed eaters; lining gloves to protect from flames, handlingice, and/or for preparing food (including pastry preparation).

Other examples of protective flexible heat shielding applications inwhich the heat-dissipating layer 120 can be used include gloves (e.g.,fire pit gloves, gloves/forearm shields for operating two-stroke engineyard equipment), integrated in uniforms (e.g., nurses/scrub techniciansin operating rooms vs. electro cautery), motorcyclist (clothing)protection from tail pipes, protective shielding in radio pouches (e.g.,protecting person from radio heat, protecting radio from heatingbattery, protecting battery from heating radio, protecting battery fromexternal heat sources), protection on the bottom of a laptop (inside thelaptop housing), protection layer from heat of laptop for laps (e.g.,lap tray) and expensive furniture (e.g., furniture pad), and portableprotective heat shield (e.g., protect sensitive electronics and persons,varies in sizes).

FIG. 2A is a perspective view of a radio holder article 200 into whichthe heat-shielding or blocking and/or heat-dissipating layer 120 isinstalled. The radio holder article 200 is an example of equipment thatmay be used by military personnel. The radio holder article 200 is butone example of using the heat-shielding or blocking and/orheat-dissipating layer 120 for dissipating heat from an article.Military radios often get hot and can cause burns to the user.

The radio holder article 200 can be removably held in a pouch 210 andworn on a user's belt 230. FIG. 2B is a view of the radio holder article200 removed from the pouch 210. In this example, a structure, such asthe structure 115 of FIG. 1D, is formed separately and then insertedinto the pouch 210 of the radio holder article 200. In another example,in the case of the structure 105 of FIG. 1B, the radio holder article200 itself serves as the second substrate 130. This allows the radioholder article 200 to be easily removed from the pouch 210. It alsoprovides for retrofitting the pouch with heat protection from theheat-shielding or blocking and/or heat-dissipating material layer orcoating.

Alternatively, the radio holder article 200 is permanently held in thepouch 210. The pouch 210 is formed using a structure, such as thestructure 100 of FIG. 1A. The pouch 210 includes a pouch attachmentladder system (PALS) adapted to attach the pouch to a load-bearingplatform (e.g., belt, rucksack, vest). In a preferred embodiment, thepouch 210 is MOLLE-compatible. “MOLLE” means Modular LightweightLoad-carrying Equipment, which is the current generation of load-bearingequipment and backpacks utilized by a number of North Atlantic TreatyOrganization (NATO) armed forces.

In this example, the heat-shielding or blocking and/or heat-dissipatinglayer 120 protects the user from heat from the radio (not shown), theheat shielding or blocking and/or heat-dissipating layer 120 protectsthe radio (not shown) from any external heat source (e.g., a hotvehicle), and the heat shielding or blocking and/or heat-dissipatinglayer 120 reduces the heat profile of the radio (not shown).

In a preferred embodiment, the substrate 225 can be formed of anyflexible, durable, and waterproof or at least water resistant material.For example, the substrate 225 can be comprised of polyester, polyvinylchloride (PVC)-coated polyester, vinyl-coated polyester, nylon, canvas,PVC-coated canvas, or polycotton canvas. The exterior finish of thesubstrate 225 can be any color, such as white, brown, or green, or anypattern, such as camouflage, as provided herein, or any other camouflagein use by the military.

Representative camouflages include, but are not limited to, universalcamouflage pattern (UCP), also known as ACUPAT or ARPAT or Army CombatUniform; MultiCam, also known as Operation Enduring Freedom CamouflagePattern (OCP); Universal Camouflage Patter-Delta (UCP-Delta); AirmanBattle Uniform (ABU); Navy Working Uniform (NWU), including variants,such as, blue-grey, desert (Type II), and woodland (Type III); MARPAT,also known as Marine Corps Combat Utility Uniform, including woodland,desert, and winter/snow variants; Disruptive Overwhite Snow digitalcamouflage, and Tactical Assault Camouflage (TACAM).

FIG. 3 and FIG. 4 are a perspective view and an exploded view,respectively, of a flexible solar panel article 300 into which theheat-shielding or blocking and/or heat-dissipating layer 120 isinstalled. The flexible solar panel article 300 is another example ofequipment that may be used by military personnel. The flexible solarpanel article 300 is but another example of using the heat shielding orblocking and/or heat-dissipating layer 120 for shielding or blockingexternal heat to and/or dissipating heat from an article.

In this example, the flexible solar panel article 300 is a flexiblesolar panel that can be folded up and carried in a backpack and thenunfolded and deployed as needed. The flexible solar panel article 300 isused, for example, to charge rechargeable batteries or to powerelectronic equipment directly.

The flexible solar panel article 300 is a multilayer structure thatincludes multiple solar modules 322 mounted on a flexible substrate,wherein the flexible substrate with the multiple solar modules 322 issandwiched between two layers of fabric. Windows are formed in at leastone of the two layers of fabric for exposing the solar modules 322.

A hem 324 may be provided around the perimeter of the flexible solarpanel article 300. In one example, the flexible solar panel article 300is about 36×36 inches. The output of any arrangement of solar modules322 in the flexible solar panel article 300 is a direct current (DC)voltage. Accordingly, the flexible solar panel article 300 includes anoutput connector 326 that is wired to the arrangement of solar modules322. The output connector 326 is used for connecting any type of DC loadto the flexible solar panel article 300. In one example, the flexiblesolar panel article 300 is used for supplying power a device, such as aDC-powered radio. In another example, the flexible solar panel article300 is used for charging a battery.

The flexible solar panel article 300 includes a solar panel assembly 328that is sandwiched between a first fabric layer 330 and a second fabriclayer 332. The first fabric layer 330 and the second fabric layer 332can be formed of any flexible, durable, and substantially waterproof orat least water resistant material, such as but not limited to,polyester, PVC-coated polyester, vinyl-coated polyester, nylon, canvas,PVC-coated canvas, and polycotton canvas. The first fabric layer 330 andthe second fabric layer 332 can be any color or pattern, such as thecamouflage pattern shown in FIG. 3 and FIG. 4.

The solar panel assembly 328 of the flexible solar panel article 300includes the multiple solar modules 322 mounted on a flexible substrate334. A set of windows or openings 340 is provided in the first fabriclayer 330 for exposing the faces of the solar modules 322. The flexiblesubstrate 334 is formed of a material that is lightweight, flexible(i.e., foldable or rollable), printable, and substantially waterproof orat least water resistant.

In the flexible solar panel article 300, the heat-dissipating layer 120is incorporated into the layers of fabric that form the flexible solarpanel article 300, in similar fashion to the structure 100 of FIG. 1A.Namely, the heat-dissipating layer 120 is provided at the back of solarmodules 322, between the flexible substrate 334 and the second fabriclayer 332. In this example, the first fabric layer 330, the flexiblesubstrate 334, the heat-dissipating layer 120, and the second fabriclayer 332 are held together by stitching and/or by a hook-and-loopfastener system.

In this example, the heat-shielding or blocking and/or heat-dissipatinglayer 120 protects the user from heat from the back of the flexiblesolar panel article 300, the heat-shielding or blocking and/orheat-dissipating layer 120 protects the back of the flexible solar panelarticle 300 from any external heat source (not shown), and theheat-dissipating layer 120 reduces the heat profile of the flexiblesolar panel article 300.

FIGS. 5-7 are perspective views of a portable battery pack 500 intowhich the heat dissipating material is installed. The portable batterypack 500 is an example of equipment that may be used by militarypersonnel. The portable battery pack 500 is but one example of using theheat-shielding or blocking and/or heat-dissipating layer 120 fordissipating heat from an article. In a preferred embodiment, theportable battery pack comprises a portable battery pack such as thatdisclosed in US Publication No. 20160118634 or U.S. application Ser. No.15/720,270, each of which is incorporated herein by reference in itsentirety.

Portable battery pack 500 comprises a pouch 510 for holding a battery550. Pouch 510 is a wearable pouch or skin that can be sized in anymanner that substantially corresponds to a size of battery 550. In oneexample, pouch 510 is sized to hold a battery 550 that is about 9.75inches long, about 8.6 inches wide, and about 1 inch thick.

Pouch 510 is formed of any flexible, durable, and substantiallywaterproof or at least water resistant material. For example, pouch 510can be formed of polyester, polyvinyl chloride (PVC)-coated polyester,vinyl-coated polyester, nylon, canvas, PVC-coated canvas, or polycottoncanvas. The exterior finish of pouch 510 can be any color, such aswhite, brown, or green, or any pattern, such as camouflage, as providedherein, or any other camouflage in use by the military. For example, inFIG. 5, FIG. 6, and FIG. 7, pouch 510 is shown to have a camouflagepattern.

Representative camouflages include, but are not limited to, universalcamouflage pattern (UCP), also known as ACUPAT or ARPAT or Army CombatUniform; MultiCam, also known as Operation Enduring Freedom CamouflagePattern (OCP); Universal Camouflage Patter-Delta (UCP-Delta); AirmanBattle Uniform (ABU); Navy Working Uniform (NWU), including variants,such as, blue-grey, desert (Type II), and woodland (Type III); MARPAT,also known as Marine Corps Combat Utility Uniform, including woodland,desert, and winter/snow variants; Disruptive Overwhite Snow digitalcamouflage, and Tactical Assault Camouflage (TACAM).

Pouch 510 has a first side 512 and a second side 514. Pouch 510 alsocomprises an opening 516, which is the opening through which battery 550is fitted into pouch 510. In one example, opening 516 is opened andclosed using a zipper, as such pouch 510 includes a zipper tab 518.Other mechanisms, however, can be used for holding opening 516 of pouch510 open or closed, such as, a hook and loop system (e.g., VELCRO®),buttons, snaps, hooks, and the like. Further, an opening 520 (see FIG.6, FIG. 7, FIG. 9) is provided on the end of pouch 510 that is oppositeopening 516. For example, opening 520 can be a 0.5-inch long slit or a0.75-inch long slit in the edge of pouch 510.

In one embodiment, the pouch is a multi-layer structure, such as thestructure 100 of FIG. 1A, including at least one layer of theheat-dissipating layer. In this embodiment, the heat-dissipating layeris permanently attached to the pouch. Alternatively, a structure, suchas the structure 115 of FIG. 1D, is formed separately and then insertedinto the pouch 510 of the portable battery pack 500. This allows theuser to retrofit an existing pouch with heat protection. The retrofitstructure comprises a structure, such as the structure 115 of FIG. 1D,for protecting the first side 512 and/or the second side 514. Theretrofit structure comprises a large structure that is operable to wraparound the battery 550 in an alternative embodiment.

In one example, battery 550 is a rechargeable battery that comprises twoleads 552 (e.g., leads 552 a, 552 b). Each lead 552 can be used for boththe charging function and the power supply function. In other words,leads 552 a, 552 b are not dedicated to the charging function only orthe power supply function only, both leads 552 a, 552 b can be used foreither function at any time. In one example, one lead 552 can be usedfor charging battery 550 while the other lead 552 can be usedsimultaneously for supplying power to equipment, or both leads 552 canbe used for supplying power to equipment, or both leads 552 can be usedfor charging battery 550. In a preferred embodiment, the leads 552 are afemale circular type of connector (TAJIMI™ part number R04-P5f).

With respect to using battery 550 with pouch 510, first the user unzipsopening 516, then the user inserts one end of battery 550 that has, forexample, lead 552 b through opening 516 and into the compartment insidepouch 510. At the same time, the user guides the end of lead 552 bthrough opening 520, which allows the housing of battery 550 to fitentirely inside pouch 510, as shown in FIG. 5. Lead 552 a is leftprotruding out of the unzipped opening 516. Then the user zips opening516 closed, leaving zipper tab 518 snugged up against lead 552 a, asshown in FIG. 6 and FIG. 7. Namely, FIG. 6 shows portable battery pack500 with side 512 of pouch 510 up, whereas FIG. 7 shows portable batterypack 500 with side 514 of pouch 510 up.

Pouch 510 of portable battery pack 500 can be MOLLE-compatible. “MOLLE”means Modular Lightweight Load-carrying Equipment, which is the currentgeneration of load-bearing equipment and backpacks utilized by a numberof NATO armed forces. Namely, pouch 510 incorporates a pouch attachmentladder system (PALS), which is a grid of webbing used to attach smallerequipment onto load-bearing platforms, such as vests and backpacks. Forexample, the PALS grid consists of horizontal rows of 1-inch (2.5 cm)webbing, spaced about one inch apart, and reattached to the backing at1.5-inch (3.8 cm) intervals. Accordingly, a set of straps 522 (e.g.,four straps 522) are provided on one edge of pouch 510 as shown.Further, four rows of webbing 524 are provided on side 512 of pouch 510,as shown in FIG. 7. Additionally, four rows of slots or slits 526 areprovided on side 514 of pouch 510, as shown in FIG. 7.

FIGS. 8-10 are perspective views of an example of wearable pouch 510 ofthe portable battery pack 500. Namely, FIG. 8 shows details of side 512of pouch 510 and of the edge of pouch 510 that includes opening 516.FIG. 8 shows opening 516 in the zipper closed state. Again, four rows ofwebbing 524 are provided on side 512 of pouch 510. FIG. 9 also showsdetails of side 512 of pouch 510, but showing the edge of pouch 510 thatincludes opening 520. FIG. 10 shows details of side 514 of pouch 510 andshows the edge of pouch 510 that includes opening 516. FIG. 10 showsopening 516 in the zipped closed state. Again, four rows of slots orslits 526 are provided on side 514 of pouch 510.

FIGS. 11A-11E illustrate various other views of wearable pouch 110 ofthe portable battery pack 100. FIG. 11A shows a view (i.e., “PLAN-A”) ofside 112 of pouch 110. FIG. 11B shows a side view of pouch 110. FIG. 11Cshows a view (i.e., “PLAN-B”) of side 114 of pouch 110. FIG. 11D showsan end view (i.e., “END-A”) of the non-strap end of pouch 110. FIG. 11Eshows an end view (i.e., “END-B”) of the strap 112-end of pouch 110.

FIG. 12A is an exploded view of an example of battery 550 of theportable battery pack 500. Battery 550 includes a battery element 564that is housed between a battery cover 554 and a back plate 562. Batteryelement 564 supplies leads 552 a, 552 b. In one example, the output ofbattery element 564 can be from about 5 volts DC to about 90 volts DC atfrom about 0.25 amps to about 10 amps.

FIG. 12B illustrates an exploded view of an example of a battery 550 ofthe portable battery pack 500 into which the heat dissipating materialis installed. Battery 550 includes a battery element 564 that is housedbetween a battery cover 554 and a back plate 562. A firstheat-dissipating layer 570 is between the battery cover 554 and thebattery element 564. The first heat-dissipating layer 570 protects thebattery from external heat sources (e.g., a hot vehicle). A secondheat-dissipating layer 572 is between the battery element 564 and theback plate 562. The second heat-dissipating layer 572 protects the userfrom heat given off by the battery element 564.

Battery cover 554 comprises a substantially rectangular compartment 556that is sized to receive battery element 564. A top hat style rim 558 isprovided around the perimeter of compartment 556. Additionally, twochannels 560 (e.g., channels 560 a, 560 b) are formed in battery cover554 (one on each side) to accommodate the wires of leads 552 a, 552 bpassing therethrough.

The leads 552 are preferably flexible and omnidirectional. Each lead 552includes a connector portion and a wiring portion. The connector portioncan be any type or style of connector needed to mate to the equipment tobe used with battery 550 of portable battery pack 500. The wiringportion is electrically connected to the battery element 564.

The wiring portion is fitted into a channel 560 formed in battery cover554 such that the connector portion extends away from battery cover 554.A spring is provided around the wiring portion, such that a portion ofthe spring is inside battery cover 554 and a portion of the spring isoutside battery cover 554. In one example, the spring is a steel springthat is from about 0.25 inches to about 1.5 inches long. The wiringportion of lead 552 and the spring are held securely in the channel 560of the battery cover 554 via a clamping mechanism.

The presence of the spring around the wiring portion of lead 552 allowslead 552 to be flexed in any direction for convenient connection toequipment from any angle. The presence of the spring around the wiringportion of lead 552 also allows lead 552 to be flexed repeatedly withoutbreaking and failing. The design of leads 552 provides benefit overconventional leads and/or connectors of portable battery packs that arerigid, wherein conventional rigid leads allow connection from one angleonly and are prone to breakage if bumped.

Battery cover 554 and back plate 562 can be formed of plastic using, forexample, a thermoform process or an injection molding. Back plate 562can be mechanically attached to rim 558 of battery cover 554 via, forexample, an ultrasonic spot welding process or an adhesive.Additionally, a water barrier material, such as silicone, may be appliedto the mating surfaces of rim 558 and back plate 562. Battery cover 554,back plate 562, and battery element 564 can have a slight curvature orcontour for conforming to, for example, the user's vest, backpack, orbody armor. In one example, the outward curve of body armor was reverseengineered so that the portable battery pack matches the curvature ofthe load bearing equipment. Advantageously, this means that the portablebattery pack does not jostle as the operator moves, which results inless energy expenditure when the operator moves.

FIG. 13 and FIG. 14 are perspective views of battery 550 of the portablebattery pack 500 when fully assembled. Namely, FIG. 13 show a view ofthe battery cover 554-side of battery 550, while FIG. 14 shows a view ofthe back plate 562-side of battery 550.

FIG. 15 illustrates an exploded view of an example of a housing of abattery 1500 into which the heat-shielding or blocking and/orheat-dissipating material is provided as a coating or layer. The battery1500 is an example of equipment that may be used by military personnel.The battery 1500 is but one example of using the heat-shielding orblocking, heat-dissipating layer 120 for dissipating heat from anarticle.

The battery 1500 includes a lid 1502 and a base 1504. The base 1504 hasa mounting plaque 1510 for mounting a latch on the base. The base 1504has a recessed hole 1508 for a connector on both sides of the base 1504.The lid 1502 includes holes 1512 to attach the lid to the base 1504. Thebase 1504 includes holes 1514 to attach the lid to the base of thehousing. Screws (not shown) are placed through holes 1512 and 1514 toattach the lid to the base. The lid 1502 includes a hole 1516 formounting a connector.

In one embodiment, the battery housing or base 1504 with sides dependingupwards therefrom is a unitary and integrally formed piece of plasticformed via injection molding. Advantageously, when the heat-shielding orblocking and/or heat-dissipating material is utilized in conjunctionwith the base, the base can be manufactured from much thinner plasticthan in prior art battery housings because the heat-shielding orblocking and/or heat-dissipating material effectively blocks, shieldsfrom, and dissipates heat. In contrast, prior art plastic batteryhousings require thicker plastic to provide heat blocking, shielding,and dissipation. When used in conjunction with the heat-shielding orblocking and/or heat-dissipating material, the thin plastic materialrequirement of the present invention provides for cost and/or weightsavings over the prior art. In fact, some embodiments of the housing ofthe present invention use materials and types of materials whichtraditionally have been disfavored because of the heat generated frombattery cells. Such materials include by way of example not limitation,aluminum, titanium, nickel, magnesium, microlattice metals, compositemetal foams, and combinations thereof. Notably, many of these materialswere previously disfavored for the base because of the heat transfer anddissipation from the battery cells. Materials which provide otheradvantages such as bullet resistance, such as composite metal foams, arealso used for the base in one embodiment of the present invention.

The battery housing or base 1504 for removably holding at least onebattery cell is coated with a paint 1506 for reducing electromagneticinterference. In a preferred embodiment, the paint 1506 includes copper.Although the base 1504 of the battery 1500 is coated with the paint1506, which functionally protects the bottom and sides of the batteryfrom external heat, the top of the battery is exposed to external heatwhen attached to heat generating equipment (e.g., radio). Since externalheat can damage the battery and/or cause it to overheat, theheat-shielding or blocking and/or heat-dissipating material layer orcoating is functionally constructed and configured within the interiorof the housing or base to protect the removable battery cells disposedtherein. In this particular example, the radio in constant use generatesa significant heat profile and the heat-shielding material is operableto block that external heat emanating from the radio. The material isfurther functional to dissipate heat generated by the at least onebattery during operation of the radio, which draws power from the atleast one battery, and reduces the heat profile of the at least onebattery cell disposed within the housing or base. Reducing the exposureof the battery cells to heat results in longer and more reliable batteryperformance.

In another example of embodiments of the present invention, theheat-shielding or blocking and/or heat-dissipating material completelycovers the interior of a housing having a plurality of battery cellsremovably disposed therein. Other examples include a heat-shielding orblocking and/or heat-dissipating material layer having anti-static,anti-radio frequency (RF), anti-electromagnetic interference (EMI),anti-tarnish, and/or anti-corrosion materials and properties thateffectively protect battery-operated devices and/or the batteries thatpower them from damage or diminished operation.

The battery housing or base 1504 includes a plurality of sealed batterycells or individually contained battery cells, i.e. batteries with theirown casings, removably disposed therein. In a preferred embodiment, thebattery cells are electrochemical battery cells, and more preferably,include lithium ion rechargeable batteries. In one embodiment, thebattery cells are lithium ferrous phosphate or all-solid-state cells(e.g., using glass electrolytes and alkaline metal anodes). In oneembodiment, the battery cells are 18350, 14430, 14500, 18500, 16650,18650, 21700, or 26650 cylindrical cells. The plurality of battery cellsmay be constructed and configured in parallel, series, or a combination.Preferably, the plurality of battery cells is removably disposed withinthe base or battery housing or container. For example, the plurality ofbattery cells can be replaced if they no longer hold a sufficientcharge.

In an alternative embodiment, one or more of the plurality of batterycells is sealed within the base. In another embodiment, the lid 1502 ispermanently secured to the base 1504.

FIG. 16 illustrates a view of an example of a battery base 1504. Thebase 1504 is shown with a latch 1520. The latch 1520 is operable toattach the battery 1500 to a military radio (e.g., AN/PRC-117G) with acorresponding catch. A dust cap 1518 is attached to the battery base1504 via a lanyard 1522 attached to the mounting plaque of the latch.The length of the lanyard 1522 is such that no part of the dust cap 1518is capable of moving underneath the battery 1500. Batteries often havethe dust cap attached to the housing via a dress nut, which allows thedust cap to move underneath the battery. When the dust cap is underneaththe battery, the battery (and any equipment attached to the battery) maybecome unstable and tip over. If the dust cap is underneath the battery,it may lead to the dust cap being torn from the housing. The batteryconnector would no longer be protected from dust and other environmentalcontaminants, causing battery failure in the field.

FIG. 17 illustrates another view of an example of a battery base 1504.In a preferred embodiment, the recessed hole 1508 includes a flat side1530 for installing a connector with a keyway. A right-angle cable isused to connect the battery to external power consuming devices and/orexternal power sources. The keyway ensures that the right-angle cabledoes not interfere with latches used to attach the battery to the radio.The keyway in FIG. 17 forces the cable to a 30.0° angle. In anotherembodiment, the keyway forces the cable at an angle between 5° and 15°away from the latch. Other angles are compatible with the presentinvention.

FIGS. 18A-D illustrate various other views of the lid.

FIGS. 19A-F illustrate various other views of the base.

FIG. 20 illustrates a view of a BA-5590 female connector. In a preferredembodiment, the BA-5590 female connector is installed in the hole 1516of the lid. The base of the connector in FIG. 20 is 0.25 inches shorterthan other similar female connectors, which results in less wasted spaceinside the battery housing. The shorter connector allows the base to be0.25 inches shorter, which results in cost, weight, and volume savingsover the prior art.

FIG. 21 illustrates a block diagram of one embodiment of a portablepower case into which the heat dissipating material is installed. Theportable power case 2100 is an example of equipment that may be used bymilitary personnel. The portable power case 2100 is but one example ofusing the heat-shielding or blocking and/or heat-dissipating layer 120for dissipating heat from and/or reducing the thermal effects of anarticle.

The portable power case has at least two access ports, at least twoleads, or at least one access port and the at least one lead accessiblypositioned on the exterior surface of the hard case. The portable powercase 2100 in FIG. 21 has four access ports 2120A-2120D and two USB ports2122A-2122B. The portable power case 2100 is operable to connect to anamplifier 2104 through an access port (e.g., 2120A). The amplifier 2104connects to a radio 2102. The portable power case 2100 is operable to becharged using a solar panel 2106 when connected to an access port (e.g.,2120B). The portable power case 2100 is operable to charge a wearablebattery 2108. The portable power case 2100 and the wearable battery 2108are connected through a DC-DC converter cable 2110 that is in contactwith an access port (e.g., 2120C). The portable power case 2100 isoperable to be charged using a vehicle battery 2112. The vehicle battery2112 is operable to charge the portable power case 2100 for a briefperiod after the ignition of the vehicle is turned off. The systemincludes a battery protector 2114 connected to an access port (e.g.,2120D) to prevent the vehicle battery from being drained. The batteryprotector 2114 is connected to the access port 2120D through a DC-DCconverter cable 2116. The USB ports 2122A-2122B are operable to chargeelectronic devices, including, but not limited to, a mobile phone 2130and/or a tablet 2132.

In a preferred embodiment, the amplifier is a 50W wideband vehicularamplifier adapter (e.g., RF-7800UL-V150 by Harris Corporation) or apower amplifier for the Falcon III VHF handheld radio (e.g.,RF-7800V-V50x by Harris Corporation). In a preferred embodiment, theradio is a PRC-117G. In an alternative embodiment, the radio is a Link16 radio (e.g., BATS-D AN/PRC-161 Handheld Link 16 Radio). Alternativeradios and/or amplifiers are compatible with the present invention.

The portable power case includes at least one battery that isselectively removable from the portable power case. In a preferredembodiment, the at least one battery is in a housing for mating with amilitary radio (e.g., PRC-117G, PRC-117F). Alternatively, one or more ofthe at least one battery is a wearable battery. The batteries in theportable power case housing can be split apart amongst members of a teamfor transport to a location. This is advantageous in that it allows alarge quantity of lithium ion batteries to arrive by air that otherwisecould not be transported due to regulations. Team members can also use asingle battery for a single military radio should rapid egress becomenecessary. This allows for maintaining communication even though thelarger case and amplifier are abandoned. Further, the cables that attachto the outside of the portable power case are compatible with thebatteries inside the portable power case, such that a second set ofcables is not needed to power equipment if the batteries are removedfrom the portable power case. Additionally, if the portable power caseis damaged in a combat related incident (e.g., damaged by an improvisedexplosive device or gunfire), the individual batteries could still workand provide power on their own.

In an alternative embodiment, one or more of the at least one batterydoes not have a housing for the plurality of battery cells, whichreduces the weight and dimensions of the portable power case 2100.Soldiers often carry 60-100 lbs. of gear in their rucksack or attachedto their vest. Additional weight slows soldiers down and also makes itmore likely that they will suffer injuries to their body (e.g., injuriesto the back, shoulders, hips, knees, ankles, and feet). Advantageously,removing the housing for one or more of the at least one battery allowsthe portable power case to be sized to fit in a rucksack. In oneembodiment, the one or more of the at least one battery without ahousing is sealed within the portable power case to prevent a user fromtampering with the plurality of battery cells. In another embodiment,the battery cells are sealed in flashspun high-density polyethylene(e.g., DUPONT™ TYVEK®), heat shrink tubing, or polyimide film (e.g.,DUPONT™ KAPTON®). In yet another embodiment, one or more of the at leastone battery is made of at least one pouch cell. Pouch cells provideefficient use of space and lighter weight, but may result in a reductionof run time.

FIG. 22 illustrates a block diagram showing the inside of one embodimentof the portable power case 2100. The portable power case 2100 includestwo batteries 2202A-2202B and three batteries 2204A-2204C disposedwithin an open interior space of the hard case. In a preferredembodiment, the batteries 2202A-2202B are 29.4V lithium ion rechargeablebatteries in a housing for mating with a PRC-117G radio. In a preferredembodiment, the batteries 2204A-2204C are 29.4V lithium ion rechargeablebatteries in a housing for mating with a PRC-117F radio. Alternativevoltages, housings, and/or number of batteries are compatible with thepresent invention. The batteries 2202A-2202B and 2204A-2204C areremovably connected to a PCB 2206 by a harness. The harness consists ofcables with connectors that allow the batteries 2202A-2202B and2204A-2204C to easily connect to the PCB 2206 by simply pushing aconnector into a corresponding battery. The harness reduces thecomplexity of electrically connecting the batteries and the PCB. Theharness preferably uses slip away connectors that allow for the quickinsert and quick release when multiple batteries are put in parallel. Inone embodiment, the slip away connectors are based on a FISCHER® 105 A87connector. In a preferred embodiment, the batteries 2202A-2202B and2204A-2204C include a heat-dissipating layer between the lid and theplurality of electrochemical battery cells.

In an alternative embodiment, the portable power case 2100 hasconnectors for the at least one battery hard mounted to the base of thehard case. This allows the at least one battery to mate on top of thehard-mounted connectors and reduces the cables within the case.

The PCB 2206 is disposed within an open interior space of the hard case.The PCB 2206 is preferably mounted in the base of the portable powercase 2100. In a preferred embodiment, the PCB 2206 is secured to thebase of the portable power case 2100 via posts that float the PCB 2206above the bottom of the hard case. The PCB 2206 is preferably protectedfrom the at least one battery by foam. In one embodiment, the foam is apolyethylene foam (e.g., ETHAFOAM®).

FIG. 23 illustrates a block diagram of the connections to the PCB in apreferred embodiment. The PCB 2206 has four inputs. Batteries 2202A and2202B are in parallel with each other and connected to the PCB at INPUT1. Battery 2204A is connected to the PCB at INPUT 2. Battery 2204B isconnected to the PCB at INPUT 3. Battery 2204C is connected to the PCBat INPUT 4. The four inputs are in parallel with each other. In apreferred embodiment, a capacitor is installed between each of thebatteries in parallel to reduce the risk of shorting the connectors. ThePCB 2206 has five outputs. OUTPUT 1 powers access port 2120A, OUTPUT 2powers access port 2120B, OUTPUT 3 powers access port 2120C, OUTPUT 4powers access port 2120D, and OUTPUT USB powers USB ports 2122A and2122B. In a preferred embodiment, access ports 2120A-2120D have the sameoutput voltage.

In an alternative embodiment, access ports 2120A-2120D include at leasttwo different output voltages. The PCB includes at least one voltageconverter for achieving the at least two different output voltages. Inone example, an access port has an output voltage equivalent to theinput voltage of the at least one battery (e.g., 29.4V) and a secondaccess port has a lower output voltage (e.g., 16.8V). The PCB includes avoltage converter to convert the input voltage of the at least onebattery to the lower output voltage of the second access port.

The PCB does not use ferrite beads to reduce noise in one embodiment. Ina first trial, ferrite beads were installed and the connectors failed.In a second trial, two ferrite beads were installed in parallel and theconnectors failed. The connectors worked after the ferrite beads wereremoved. The ferrite beads did not have sufficient current capability.The PCB uses capacitors to protect the batteries in another embodiment.

In one embodiment, the PCB includes at least one processor. By way ofexample, and not limitation, the processor may be a general-purposemicroprocessor (e.g., a central processing unit (CPU)), a graphicsprocessing unit (GPU), a microcontroller, a Digital Signal Processor(DSP), an Application Specific Integrated Circuit (ASIC), a FieldProgrammable Gate Array (FPGA), a Programmable Logic Device (PLD), acontroller, a state machine, gated or transistor logic, discretehardware components, or any other suitable entity or combinationsthereof that can perform calculations, process instructions forexecution, and/or other manipulations of information.

One or more of the at least one processor is incorporated into controlelectronics used to determine the state of charge (SOC) of the portablepower case in one embodiment. Examples of state of charge indicators aredisclosed in US Publication Nos. 20170269162 and 20150198670, each ofwhich is incorporated herein by reference in its entirety.

FIG. 24 illustrates a block diagram of one embodiment of the controlelectronics for a state of charge indicator incorporated into theportable power case. In this example, the control electronics 2430includes a voltage sensing circuit 2432, an analog-to-digital converter(ADC) 2434, a processor 2436, the indicator 2440, and optionally adriver 2442.

The voltage sensing circuit 2432 can be any standard voltage sensingcircuit, such as those found in volt meters. An input voltage VIN issupplied via the power BUS. In one embodiment, the voltage sensingcircuit 2432 is designed to sense any direct current (DC) voltage in therange of from about 0 volts DC to about 50 volts DC. In one embodiment,the voltage sensing circuit 2432 includes standard amplification orde-amplification functions for generating an analog voltage thatcorrelates to the amplitude of the input voltage VIN that is present.The ADC 2434 receives the analog voltage from the voltage sensingcircuit 2432 and performs a standard analog-to-digital conversion.

The processor 2436 manages the overall operations of the SOC indicator.The processor 2436 is any controller, microcontroller, or microprocessorthat is capable of processing program instructions.

The indicator 2440 is any visual, audible, or tactile mechanism forindicating the state of charge of the portable power case. A preferredembodiment of a visual indicator is at least one 5-bar liquid crystaldisplay (LCD), wherein five bars flashing or five bars indicatesgreatest charge and one bar or one bar flashing indicates least charge.Another example of a visual indicator is at least one seven-segmentnumeric LCD, wherein the number 5 flashing or the number 5 indicatesgreatest charge and the number 1 or the number 1 flashing indicatesleast charge. Alternatively, the at least one LCD displays the voltageof the portable power case as measured by the control electronics.

The at least one LCD is preferably covered with a transparent material.In a preferred embodiment, the cover is formed of a clear plastic (e.g.,poly(methyl methacrylate)). This provides an extra layer of protectionfor the at least one LCD, much like a screen protector provides an extralayer of protection for a smartphone. This increases the durability ofthe at least one LCD. The portable power case includes a waterproofsealant (e.g., silicone) around the cover.

Alternatively, a visual indicator is at least one LED. One preferredembodiment of a visual indicator is a set of light-emitting diodes(LEDs) (e.g., 5 LEDs), wherein five lit LEDs flashing or five lit LEDsindicates greatest charge and one lit LED or one lit LED flashingindicates least charge. In one embodiment, the LEDs are red, yellow,and/or green. In one example, two of the LEDs are green to indicate amostly full charge on the portable power case, two of the LEDs areyellow to indicate that charging will soon be required for the portablepower case, and one LED is red to indicate that the portable power caseis almost drained. In a preferred embodiment, at least three bars,lights, or numbers are used to indicate the state of charge.

In one embodiment, the at least one LED is preferably covered with atransparent material. In a preferred embodiment, the cover is formed ofa clear plastic (e.g., poly(methyl methacrylate)). This provides anextra layer of protection for the at least one LED. This increases thedurability of the at least one LED. The portable power case includes awaterproof sealant (e.g., silicone) around the cover.

One example of an audible indicator is any sounds via an audio speaker,such as beeping sounds, wherein five beeps indicates greatest charge andone beep indicates least charge. Another example of an audible indicatoris vibration sounds via any vibration mechanism (e.g., vibration motorused in mobile phones), wherein five vibration sounds indicates greatestcharge and one vibration sound indicates least charge.

One example of a tactile indicator is any vibration mechanism (e.g.,vibration motor used in mobile phones), wherein five vibrations indicategreatest charge and one vibration indicate least charge. Another exampleof a tactile indicator is a set of pins that rise up and down to be feltin Braille-like fashion, wherein five raised pins indicates greatestcharge and one raised pin indicates least charge.

In one example, the processor 2436 is able to drive indicator 2440directly. In one embodiment, the processor 2436 is able to drivedirectly a 5-bar LCD or a seven-segment numeric LCD. In another example,however, the processor 2436 is not able to drive indicator 2440directly. In this case, the driver 2442 is provided, wherein the driver2442 is specific to the type of indicator 2440 used in the controlelectronics 2430.

Additionally, the processor 2436 includes internal programmablefunctions for programming the expected range of the input voltage VINand the correlation of the value the input voltage VIN to what isindicated at the indicator 2440. In other words, the discharge curve ofthe portable power case can be correlated to what is indicated atindicator 2440. In one embodiment, the processor 2436 is programmedbased on a percent discharged or on an absolute value present at theinput voltage VIN.

In one embodiment, the PCB includes at least one antenna, which allowsthe portable power case to send information (e.g., state of chargeinformation) to at least one remote device (e.g., smartphone, tablet,laptop computer, satellite phone) and/or receive information (e.g.,software updates, activation of kill switch) from at least one remotedevice. The at least one antenna provides wireless communication,standards-based or non-standards-based, by way of example and notlimitation, radiofrequency, BLUETOOTH®, ZIGBEE®, Near FieldCommunication, or similar commercially used standards.

FIG. 25A illustrates a block diagram of an example of an SOC system 2520that includes a mobile application for use with a portable power case.The SOC system 2520 includes a portable power case 2100 having acommunications interface 2510.

The communications interface 2510 is any wired and/or wirelesscommunication interface for connecting to a network and by whichinformation may be exchanged with other devices connected to thenetwork. Examples of wired communication interfaces include, but are notlimited to, USB ports, RS232 connectors, RJ45 connectors, Ethernet, andany combinations thereof. Examples of wireless communication interfacesinclude, but are not limited to, an Intranet connection, Internet, ISM,BLUETOOTH® technology, WI-FI®, WIMAX®, IEEE 802.11 technology, radiofrequency (RF), Near Field Communication (NFC), ZIGBEE®, Infrared DataAssociation (IrDA) compatible protocols, Local Area Networks (LAN), WideArea Networks (WAN), Shared Wireless Access Protocol (SWAP), anycombinations thereof, and other types of wireless networking protocols.

The communications interface 2510 is used to communicate, preferablywirelessly, with at least one remote device, such as but not limited to,a mobile phone 2130 or a tablet 2132. The mobile phone 2130 can be anymobile phone that (1) is capable of running mobile applications and (2)is capable of communicating with the portable power case. The mobilephone 2130 can be, for example, an ANDROID™ phone, an APPLE® IPHONE®, ora SAMSUNG® GALAXY® phone. Likewise, the tablet 2132 can be any tabletthat (1) is capable of running mobile applications and (2) is capable ofcommunicating with the portable power case. The tablet 2132 can be, forexample, the 3G or 4G version of the APPLE® IPAD®.

Further, in SOC system 2500, the mobile phone 2130 and/or the tablet2132 is in communication with a cellular network 2516 and/or a network2514. The network 2514 can be any network for providing wired orwireless connection to the Internet, such as a local area network (LAN)or a wide area network (WAN).

An SOC mobile application 2512 is installed and running at the mobilephone 2130 and/or the tablet 2132. The SOC mobile application 2512 isimplemented according to the type (i.e., the operating system) of mobilephone 2130 and/or tablet 2132 on which it is running. The SOC mobileapplication 2512 is designed to receive SOC information from theportable power case. The SOC mobile application 2512 indicatesgraphically, audibly, and/or tactilely, the state of charge to the user(not shown).

FIG. 25B illustrates a block diagram of an example of SOC system 2520 ofthe portable power case that is capable of communicating with the SOCmobile application 2512. In this example, the SOC system 2520 includesan SOC portion 2522 and a communications portion 2524. The SOC portion2522 is substantially the same as the control electronics 2430 shown inFIG. 24. The communications portion 2524 handles the communication ofthe SOC information to the SOC mobile application 2512 at, for example,the mobile phone 2130 and/or the tablet 2132.

The communications portion 2524 includes a processor 2526 that iscommunicatively connected to the communications interface 2510. Thedigital output of the ADC 2434 of the SOC portion 2522, which is the SOCinformation, feeds an input to the processor 2526. The processor 2526can be any controller, microcontroller, or microprocessor that iscapable of processing program instructions. One or more batteries 2528provide power to the processor 2526 and the communications interface2510. The one or more batteries 2528 can be any standard cylindricalbattery, such as quadruple-A, triple-A, or double-A, or a battery fromthe family of button cell and coin cell batteries. A specific example ofa battery 2528 is the CR2032 coin cell 3-volt battery.

In SOC system 2520, the SOC portion 2522 and the communications portion2524 operate substantially independent of one another. Namely, thecommunications portion 2524 is powered separately from the SOC portion2522 so that the communications portion 2524 is not dependent on thepresence of the input voltage VIN at the SOC portion 2522 for power.Therefore, in this example, the communications portion 2524 is operableto transmit information to the SOC mobile application 2512 at any time.However, in order to conserve battery life, in one embodiment theprocessor 2526 is programmed to be in sleep mode when no voltage isdetected at the input voltage VIN at the SOC portion 2522 and to wake upwhen an input voltage VIN is detected. Alternatively, the processor 2526is programmed to periodically measure the SOC and send SOC informationto the SOC mobile application 2512 on the at least one remote deviceperiodically, such as every hour, regardless of the state of inputvoltage VIN.

FIG. 25C illustrates a block diagram of another example of controlelectronics 2530 of the portable power case that is capable ofcommunicating with the SOC mobile application 2512. In this example, theoperation of the communications interface 2510 is dependent on thepresence of a voltage at input voltage VIN. This is because, in controlelectronics 2530, the communications interface 2510 is powered from theoutput of voltage sensing circuit 2432. Further, the processor 2436provides the input (i.e., the SOC information) to the communicationsinterface 2510. A drawback of the control electronics 2530 of FIG. 25Cas compared with the SOC system 2520 of FIG. 25B, is that it is operableto transmit SOC information to the SOC mobile application 2512 only whenthe portable power case has a charge.

In one embodiment, the portable power case includes a kill switch todeactivate the portable power case. For example, if a team of soldierscame under attack, the batteries within the portable power case housingcould be removed and the kill switch activated to render the portablepower case inoperable. A kill switch could also be used to render theportable power case inoperable at a designated expiration date forsafety purposes.

In another embodiment, the PCB includes a global positioning system(GPS) chip. The GPS chip allows the portable power case to be locatedfrom a remote location. In one example, the GPS chip allows a search andrescue team to locate hikers or campers lost in the woods. The GPS chipalso allows for the remote activation of a kill switch from anywhere inthe world. For example, if the team of soldiers came under attack andremoved the batteries within the portable power case housing, commandcould then remotely activate the kill switch to render the portablepower case inoperable.

In a preferred embodiment, the batteries 2202A-2202B are 29.4V lithiumion rechargeable batteries in a housing for mating with a PRC-117Gradio. FIG. 18A illustrates a top perspective view of a battery lid of arechargeable battery for mating with a PRC-117G radio. FIG. 18Billustrates a cross-section view of the battery lid. FIG. 18Cillustrates a side perspective view of the battery lid. FIG. 18Dillustrates another cross-section view of the battery lid.

FIG. 19A illustrates a top perspective view of a battery base of arechargeable battery for mating with a PRC-117G radio. FIG. 19Billustrates a cross-section view of the battery base. FIG. 19Cillustrates a detail view of a part of the cross-section view of thebattery base shown in FIG. 19B. FIG. 19D illustrates a side perspectiveview of the battery base. FIG. 19E illustrates another cross-sectionview of the battery base. FIG. 19F illustrates another side perspectiveview of the battery base. The batteries 2202A-2202B preferably contain acoating or layer of the heat-shielding or blocking and/orheat-dissipating material. In an alternative embodiment, at least one ofthe batteries 2202A-2202B does not have a housing, which reduces theweight and dimensions of the portable power case 2100.

In a preferred embodiment, the batteries 2204A-2204C are 29.4V lithiumion rechargeable batteries in a housing for mating with a PRC-117Fradio. FIG. 26A illustrates an angled perspective view of a rechargeablebattery in a housing for mating with a PRC-117F radio. FIG. 26Billustrates a top view of a rechargeable battery in a housing for matingwith a PRC-117F radio. FIG. 26C illustrates a side view of arechargeable battery in a housing for mating with a PRC-117F radioincluding a connector. FIG. 26D illustrates another side view of arechargeable battery in a housing for mating with a PRC-117F radio. Thebatteries 2204A-2204C preferably contain a coating or layer of theheat-shielding or blocking and/or heat-dissipating material. In analternative embodiment, at least one of the batteries 2204A-2204C doesnot have a housing, which reduces the weight and dimensions of theportable power case 2100.

The portable power case is enclosed in a hard case (e.g., PELICAN® 1500)in a preferred embodiment. The hard case is formed of polypropylene inone embodiment. The hard case is preferably waterproof or waterresistant. In one embodiment, the portable power case is sized to fit ina jerrycan holder attached to a vehicle.

FIG. 27A illustrates a view of the exterior of one embodiment of theportable power case. The case includes a top portion 2602 (e.g., a lid)and a bottom portion 2604 (e.g., a base). The top portion 2602 and thebottom portion 2604 form a housing having an interior surface, anexterior surface, and an open interior space. The case includes latches2610 for securing the contents of the case, a pressure purge valve 2612,and a handle 2614. The latches include a self-fusing silicone tape(e.g., RESCUE TAPE™) in a preferred embodiment to prevent the latchesfrom rattling, which could give away a soldier's position and/ordistract the soldier. A cap 2616 is provided to protect the USB ports.

In a preferred embodiment, the at least one battery and the at least onePCB are disposed within the open interior space of the bottom portion2604 of the portable power case. In an alternative embodiment, one ormore of the at least one PCB are disposed within the open interior spaceof the top portion 2602 of the portable power case.

The portable power case has mounting attachments (e.g., single studfittings or double stud fittings) compatible with L-track tie downsystems in one embodiment. L-track tie down systems are often installedin military vehicles and aircraft. Additionally or alternatively, theportable power case has mounting attachments compatible with A-track,E-track, F-track, and/or kaptive beam tie down systems. In a preferredembodiment, the mounting attachments are attached to the bottom portion2604 of the portable power case.

FIG. 27B illustrates a view of the exterior of another embodiment of theportable power case. A base for mounting at least one amplifier and atleast one radio 2606 is attached to the top portion 2602 through shockabsorbing cylinders 2608. A base for securing the portable power case toa vehicle 2620 is attached to the bottom portion 2604 through shockabsorbing cylinders 2618.

In a preferred embodiment, the base for mounting at least one amplifierand at least one radio 2606, the shock absorbing cylinders 2618, and thebase for securing the portable power case to a vehicle 2620 are formedfrom a shock mount interface assembly (e.g., HARRIS® 12050-3050-01).Alternative mounts are compatible with the present invention.

In an alternative embodiment, the portable power case includes the basefor mounting at least one amplifier and at least one radio 2606 attachedto the top portion 2602 through shock absorbing cylinders 2608. In oneembodiment, the portable power case has mounting attachments compatiblewith L-track, A-track, E-track, F-track, and/or kaptive beam tie downsystems. In a preferred embodiment, the mounting attachments areattached to the bottom portion 2604 of the portable power case.

FIG. 28 illustrates a view of the portable power case with the cap (notshown) removed to show the USB ports. USB ports 2122A and 2122B areaccessible on the front of the hard case.

The hard case is lined with foam in one embodiment. Additionally oralternatively, the case is lined with a material that is resistant toheat and/or electromagnetic interference. FIG. 29 shows one example ofthe portable power case 2100 lined with material resistant to heat 120.The amplifier and radio give off a significant amount of heat. The heatresistant material prevents heat transfer from the amplifier and radioto the batteries. If a lithium ion battery overheats, it reducesperformance of the battery, reduces the life span of the battery, andmay result in a fire. Further, the batteries within the portable powercase generate heat. Lining the portable power case with a materialresistant to heat decreases the heat profile of soldiers, making themless vulnerable to enemy thermal imaging technology.

Additionally, the heat resistant material may also beanti-electromagnetic interference material. The anti-electromagneticinterference material lining creates a Faraday cage and preventsdisruption by electromagnetic radiation. In an alternative embodiment,the case may be coated with an electromagnetic interference and/or radiofrequency interference shielding paint including copper, silver, nickel,and/or graphite.

The portable power case provides for modularity that allows the user todisassemble and selectively remove the batteries installed within theportable power case housing in a preferred embodiment. This modularityallows the user to comply with Survival, Evasion, Resistance, and Escape(SERE) training. In case of attack, each of the batteries can be used topower the at least one radio and/or the at least one amplifier, as wellas other gear, because each battery has its own battery managementcircuit.

As previously mentioned, shipping lithium ion batteries or devices withlithium ion batteries is banned or highly regulated in most parts of theworld due to the risk of overheating and/or fire. Advantageously, thismodularity makes it easier to ship or transport the portable power casebecause the batteries can be transported individually. In one example,the portable power case includes two batteries. A first battery can beshipped in the portable power case, while a second battery can beshipped separately from the portable power case. Then the case isreassembled and separate batteries placed back in the harness within theportable power case at the destination.

The portable power case has at least two access ports, at least twoleads, or at least one access port and the at least one lead accessiblypositioned on the exterior surface of the hard case. The at least twoaccess ports, at least two leads, or at least one access port and the atleast one lead are operable to charge the portable power case and supplypower to electronic devices. In a preferred embodiment, the portablepower case has four access ports or four leads. Each access port or leadcan be used for both the charging function and the power supplyfunction. The access ports or leads are not dedicated to the chargingfunction only or the power supply function only. The access ports orleads can be used for either function at any time. For example, if theportable power case has four access ports, all four access ports can beused for the charging the portable power case, three access ports can beused for charging the portable power case and one access port can beused to supply power to an electronic device, two access ports can beused for charging the portable power case and two access ports can beused to supply power to electronic devices, one access port can be usedfor charging the portable power case and three access ports can be usedto supply power to electronic devices, or all four access ports can beused to supply power to electronic devices.

In one embodiment, the at least two access ports, the at least twoleads, or the at least one access port and the at least one leadprioritize the charging of electronic devices. In one example, theportable power case has two access ports. The second access port willstop charging an electronic device when the available power in theportable power case is lower than a designated threshold. In anotherexample, the portable power case has four access ports. The fourthaccess port will stop charging an electronic device when the availablepower in the portable power case is lower than a first designatedthreshold, the third access port will stop charging an electronic devicewhen the available power in the portable power case is lower than asecond designated threshold, and the second access port will stopcharging an electronic device when the available power in the portablepower case is lower than a third designated threshold.

The portable power case can supply power to electronic devices that aredifferent for each access port or lead. In one example, the portablepower case is supplying power to a wearable battery and an amplifier. Inanother example, the portable power case is supplying power to fourwearable batteries.

In one embodiment, the portable power case provides power in an order ofpriority of the device and automatically cuts out devices of lowermission priority in order to preserve remaining power for higherpriority devices. In one example, a radio has a first (i.e., top)priority, a tablet has a second priority, a mobile phone has a thirdpriority, and a laser designator (e.g., Special Operations Forces LaserAcquisition Marker (SOFLAM)) has a fourth priority.

In one embodiment, the portable power case prioritizes at least onedevice by using at least one smart cable. The at least one smart cablestores information including, but not limited to, a unique identifier(e.g., MAC address) for the at least one device, power requirements ofthe at least one device, a type of device for the at least one device,and/or a priority ranking for the at least one device.

Additionally, the method used to charge the portable power case can bedifferent for each access port or lead. In one example, the portablepower case is charging using a solar panel and an AC adapter. In anotherexample, the portable power case is charging using four AC adapters.

In a preferred embodiment, the at least two access ports, at least twoleads, or at least one access port and the at least one lead are thesame type of connector (e.g., female FISCHER® 105 A87 connectors orTAJIMI™ Electronics part number R04-P5f) and provide the same outputvoltage. Alternatively, the at least two access ports, at least twoleads, or at least one access port and the at least one lead are made ofat least two different types of connectors and/or provide differentoutput voltages. Preferably, the diameter and/or shape of the connectoris different for different input voltages. In one example, an accessport or lead has a higher output voltage (e.g., 29.4V) and largerdiameter, while another access port or lead has a lower output voltage(e.g., 16.8V) and smaller diameter. This coordination of higher voltagewith larger diameter and lower voltage with smaller diameter makes itintuitive for an operator to use the correct access port or lead for thecorrect device (e.g., amplifier, radio, wearable battery, vehiclebattery, AC adapter, generator, solar panel, laser designator).Advantageously, this coordination allows an operator to associate thecorrect access port or lead with the correct device in the dark. Thus,the access port or lead is an inherent voltage selector. Further, theoperator can quickly connect devices without knowing an operatingvoltage, thereby maintaining situational awareness and eyes on combat.

FIG. 30A shows a view of one embodiment of the access ports. The accessports are preferably staggered vertically and horizontally to allow foreasy access to the ports. As shown in FIG. 30B, the preferred embodimentincludes a keyway (shown as a flat portion of the connector) to ensurecorrect orientation of cables. In one embodiment, the cables connectedto the access ports located on the top row orient downwards and thecables connected to the access ports located on the bottom row orientupwards. Alternatively, the cables connected to the access ports locatedon the top row orient downwards and the cables connected to the accessports located on the bottom row orient upwards. A gasket 2702 isprovided around each of the access ports to seal the interior of thecase from the external environment. In a preferred embodiment, theaccess ports are circular connectors (e.g., female FISCHER® 105 A087connectors or TAJIMI™ Electronics part number R04-P5f). In oneembodiment, a dust cap is provided for each of the access ports toprotect the access port from environmental elements when not in use.

In another preferred embodiment, the access ports are all orientedupwards. Advantageously, this embodiment allows an operator to quicklyconnect devices because the access ports orient in the same direction,thereby allowing the operator to develop motor memory.

FIG. 30C shows a view of one embodiment of a portable power case withleads. The leads are preferably staggered vertically and horizontally toallow for easy access to the leads. A gasket 2702 is provided aroundeach of the leads to seal the interior of the case from the externalenvironment. In one embodiment, a dust cap is provided for each of theleads to protect the leads from environmental elements when not in use.

FIG. 30D shows a cutaway view of one embodiment of a portion of theportable power case 2100, which shows more details of the leads 2704. Anexterior gasket 2702 and an interior gasket 2714 is provided around eachof the leads to seal the interior of the case from the externalenvironment. Each lead 2704 has a connector portion 2706 and a wiringportion 2708. Wiring portion 2708 is electrically connected to at leastone battery. Connector portion 2706 can be any type or style ofconnector needed to mate to the equipment to be used with the portablepower case 2100. In a preferred embodiment, the connector portion 2706is a female circular type of connector (e.g., female FISCHER® 105 A087connector, TAJIMI™ part number R04-P5f). In an alternative embodiment,at least one connector portion 2706 is a male universal serial bus(USB), micro USB, lightning, and/or Firewire connector. In anotherembodiment, the connector portion 2706 is a connector designed toprevent arc flash (e.g., MELTRIC connectors). In yet another embodiment,the connector portion 2706 has an Ingress Protection (IP) rating ofIP2X, IP3X, IP4X, IP5X, IP6X, IPX1, IPX2, IPX3, IPX4, IPX5, IPX6, IPX7,or IPX8. More preferably, the connector portion 2706 has an IP rating ofIPX6, IPX7, or IPX8. IP ratings are described in IEC standard 60529, ed.2.2 (05/2015), published by the International ElectrotechnicalCommission, which is incorporated herein by reference in its entirety.In one embodiment, the connector portion meets standards described inDepartment of Defense documents MIL-STD-202E, MIL-STD-202F publishedFeb. 1998, MIL-STD-202G published 18 Jul. 2003, and/or MIL-STD-202Hpublished 18 Apr. 2015, each of which is incorporated herein byreference in its entirety.

In a preferred embodiment, the leads 2704 are flexible omnidirectionalleads. Wiring portion 2708 is fitted into a channel formed in theportable power case 2100 such that connector portion 2706 extends awayfrom the portable power case 2100. A spring 2710 is provided aroundwiring portion 2708, such that a portion of spring 2710 is inside theportable power case 2100 and a portion of spring 2710 is outside theportable power case 2100. In one example, spring 2710 is a steel springthat is from about 0.25 inches to about 1.5 inches long. Wiring portion2708 of lead 2704 and spring 2710 are held securely in the channel ofthe portable power case 2100 via a clamping mechanism 2712.Alternatively, the wiring portion 2708 of lead 2704 and spring 2710 areheld securely in the channel of the portable power case 2100 using anadhesive, a retention pin, a hex nut, a hook anchor, and/or a zip tie.

The presence of spring 2710 around wiring portion 2708 of lead 2704allows lead 2704 to be flexed in any direction for convenient connectionto equipment from any angle. The presence of spring 2710 around wiringportion 2708 of lead 2704 also allows lead 2704 to be flexed repeatedlywithout breaking or failing. The design of leads 2704 provides benefitover conventional leads and/or connectors that are rigid, whereinconventional rigid leads allow connection from one angle only and areprone to breakage if bumped.

In one embodiment, the flexible omnidirectional leads are attached tothe portable power case via a panel mount pass through. In a preferredembodiment, the panel mount pass through is formed of metal (e.g.,aluminum). Alternatively, the flexible omnidirectional leads areattached to the portable power case with a panel mount gasket. In oneembodiment, a gasket is on the inside and/or outside of the portablepower case to seal the portable power case from environmental elements(e.g., dust, water). In one embodiment, the gasket is formed of siliconeor rubber. In another embodiment, a layer of heat shrink tubing isplaced around the wiring portion before the spring is placed around thewiring portion. The heat shrink tubing is preferably flexible.Advantageously, the heat shrink tubing provides additional waterproofingfor the battery.

The at least two access ports, at least two leads, or at least oneaccess port and the at least one lead are positioned on the left side ofthe case relative to the latches in a preferred embodiment. FIG. 31illustrates a block diagram of a portable power case in an ATV withthree passengers. The ATV 2800 has a steering wheel 2802 and a seat fora driver 2804. A seat for a first passenger 2806 is to the right of thedriver. The first passenger is responsible for maintaining the securityof the right side of the ATV. A seat for a second passenger 2808 isbehind the driver. The second passenger is responsible for maintainingthe security of the left side of the ATV. The locations of the firstpassenger and the second passenger allow for 360-degree visual coverageof the landscape surrounding the ATV. The portable power case 2100 islocated to the right of the second passenger. Placing the access portsand/or leads on the left side of the case relative to the latchesprevents the second passenger and/or gear from knocking the cablesconnected to the case loose from the access ports and/or leads. Thetrunk 2810 is available for storing additional gear.

FIG. 32 illustrates a block diagram of a portable power case in an ATVwith four passengers. The ATV 2800 has a steering wheel 2802 and a seatfor a driver 2804. A seat for a first passenger 2806 is to the right ofthe driver. A seat for a second passenger 2808 is behind the driver. Thesecond passenger is responsible for maintaining the security of the leftside of the ATV. A seat for a third passenger 2812 is to the right ofthe seat for the second passenger 2808. The portable power case 2100 isplaced in the trunk 2810.

In one embodiment, the portable power case includes at least one visualindicator for indicating the state of charge of an electronic deviceattached to an access port or lead. In one embodiment, the visualindicator is at least one LED. One preferred embodiment of a visualindicator is a set of light-emitting diodes (LEDs) (e.g., 5 LEDs),wherein five lit LEDs flashing or five lit LEDs indicates greatestcharge and one lit LED or one lit LED flashing indicates least charge.In one embodiment, the LEDs are red, yellow, and/or green. In oneexample, two of the LEDs are green to indicate a mostly full battery inthe electronic device, two of the LEDs are yellow to indicate a moderatecharge in the electronic device, and one LED is red to indicate that thebattery is almost drained in the electronic device. Additionally oralternatively, the LEDs include a blue LED to indicate that the accessport or lead is currently attached to a device that is charging theportable power case.

In one embodiment, the at least one LED is preferably covered with atransparent material. In a preferred embodiment, the cover is formed ofa clear plastic (e.g., poly(methyl methacrylate)). This provides anextra layer of protection for the at least one LED. This increases thedurability of the at least one LED. The portable power case includes awaterproof sealant (e.g., silicone) around the cover.

In an alternative embodiment, the visual indicator for indicating thestate of charge of an electronic device attached to an access port orlead is at least one LCD. A preferred embodiment of a visual indicatoris at least one 5-bar liquid crystal display (LCD), wherein five barsflashing or five bars indicates greatest charge and one bar or one barflashing indicates least charge. Another example of a visual indicatoris at least one seven-segment numeric LCD, wherein the number 5 flashingor the number 5 indicates greatest charge and the number 1 or the number1 flashing indicates least charge. Alternatively, an LCD displays thevoltage of the electronic device as measured by the control electronics.

The at least one LCD is preferably covered with a transparent material.In a preferred embodiment, the cover is formed of a clear plastic (e.g.,poly(methyl methacrylate)). This provides an extra layer of protectionfor the at least one LCD, much like a screen protector provides an extralayer of protection for a smartphone. This increases the durability ofthe at least one LCD. The portable power case includes a waterproofsealant (e.g., silicone) around the cover.

In an alternative embodiment, the state of charge of an electronicdevice attached to an access port or lead is displayed on an indicatorincorporated into to a cable attaching the electronic device to theaccess port or lead. The state of charge is preferably displayed on theindicator when a button is pressed or a switch is turned on. In oneembodiment, the cable is operable to communicate information to at leastone remote device using a mobile application.

In yet another embodiment, the state of charge of an electronic deviceattached to an access port or lead is displayed on a separate state ofcharge indicator, such as the state of charge indicators disclosed inU.S. application Ser. No. 15/612,617 and US Publication No. 20150198670,each of which is incorporated herein by reference in its entirety. Inone embodiment, the state of charge indicator is operable to be chargedusing induction charging.

The portable power case preferably includes at least one USB port forcharging electronic devices (e.g., mobile phone, tablet, smartphone,camera, global positioning system devices (GPS), thermal imagingdevices, weapon optics, watches, satellite phones, defense advanced GPSreceivers). The at least one USB port is preferably accessiblypositioned on the front side of the case. Advantageously, this positionsthe at least one USB port away from a second passenger of an ATV suchthat the second passenger's gear does not knock a USB cable loose, whileallowing the at least one USB port to remain accessible. Alternatively,the at least one USB port is accessibly positioned on the left, right,or back side of the case or in the top portion of the case (e.g., thelid).

In a preferred embodiment, the at least one USB port connects to any9-32 volt DC power input. In one embodiment, the at least one USB porthas an LED (e.g., a blue LED) that illuminates when the at least one USBport is powered on. In a preferred embodiment, at least one protectivedust cap protects the at least one USB port from environmental elements.In one embodiment, the portable power case includes two USB portsprotected by one protective dust cap. The output voltage of the at leastone USB port is 5 volts DC in one embodiment. The at least one USB porthas a charging output up to 2.1 amps per USB device (4.2 amps maximumoutput) in one embodiment. In a preferred embodiment, the at least oneUSB port is compatible with APPLE® and ANDROID™ products.

As previously mentioned, the portable power case and wearable battery2108 are connected through a DC-DC converter cable. Additionally, thebattery protector 2114 is connected to the portable power case through aDC-DC converter cable.

FIG. 33A illustrates an angled view of the housing of one embodiment ofa DC-DC converter cable. FIG. 33B shows an end view of the housing ofone embodiment of a DC-DC converter cable. FIG. 33C shows a side view ofthe housing of one embodiment of a DC-DC converter cable. FIG. 33D showsa cross-section of the housing of one embodiment of a DC-DC convertercable. FIG. 33E shows an end view of a connector end cap for the housingof one embodiment of a DC-DC converter cable. FIG. 33F shows an angledview of a connector end cap for the housing of one embodiment of a DC-DCconverter cable. FIG. 33G shows an end view of a grommet end cap for thehousing of one embodiment of a DC-DC converter cable. FIG. 33H shows anangled view of a grommet end cap for the housing of one embodiment of aDC-DC converter cable.

In a preferred embodiment, the exterior of the housing has fins todissipate heat (i.e., a heat sink). The fins provide a larger surfacearea to dissipate the heat. Additionally or alternatively, the housingof the DC-DC converter cable is formed of copper vacuum tubes encased inan aluminum extrusion. Copper has a high thermal conductivity, whichallows heat to quickly dissipate, and aluminum provides a weightsavings.

The system allows the portable power case 2100 to charge using thevehicle battery 2112 after the ignition is turned off. The systemincludes a battery protector 2114 to prevent users from being strandeddue to a drained vehicle battery 2112.

FIG. 34 illustrates a block diagram of the battery protector. Thebattery protector includes INPUT from the vehicle battery 2112 andOUTPUT to the DC-DC converter cable 2116. A green LED 3002 and a red LED3004 provide visual information regarding the current charge status. Thebattery protector includes a rotary switch 3008 to select a desired timeor voltage setting. In a preferred embodiment, the battery protector isconnected to the vehicle battery using ring terminals. Alternatively,the battery protector is connected to the vehicle battery usingalligator clips or a NATO slave adapter.

In one embodiment, the battery protector is a timer set to a time wherethe load will not drain the vehicle battery (e.g., 2 minutes, 15minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 8hours, or 12 hours). Additionally or alternatively, the batteryprotector is a low voltage disconnect (LVD) that automaticallydisconnects the load when the vehicle battery voltage falls below a setDC voltage (e.g., 10.6V, 10.8V, 11.0V, 11.2V, 11.4V, 11.6V, 11.8V,12.0V, 12.1V, or 12.2V fora 12V battery or 19V, 20V, 21V, 21.4V, 22V,22.5V, 22.8V, 23V, 24V, 24.2V, 25V, or 25.5V for a 24V battery). In oneembodiment, the battery protector automatically reconnects the load whenthe battery voltage returns to a normal value (e.g., above the set DCvoltage) after charging. The battery protector automatically detects thevehicle battery voltage (e.g., 12V or 24V) and selects a correspondingset DC voltage (e.g., 11.6V for a 12V battery or 22.8V for a 24Vbattery) in another embodiment.

The battery protector has over voltage protection that automaticallydisconnects the load when the battery protector detects a voltage higherthan a set DC voltage (e.g., above 16V) in a preferred embodiment. Inone embodiment, the battery protector automatically reconnects the loadwhen the detected voltage falls below the set DC voltage (e.g., below16V).

The battery protector includes an emergency override switch 3006 in oneembodiment. This allows the load to charge using the vehicle battery foran additional period of time (e.g., 15 minutes) in an emergency byoverriding a timed-out timer.

In a preferred embodiment, the battery protector includes a visualindicator (e.g., LED lights) to indicate a current status. In oneembodiment, the battery protector has a green LED light to indicate thatthe engine is running and the load is charging; a flashing green LEDlight to indicate that the vehicle engine is off, the timer has started,and the load is charging; a flashing red LED light to indicate that thetimer has expired and the load is no longer charging; a slow flashingred LED light to indicate that the vehicle battery voltage is below theset DC voltage and the load is no longer charging; and a solid red lightto indicate an overvoltage condition. The battery protector ispreferably waterproof Alternatively, the battery protector is waterresistant.

The system also allows the portable power case to charge using at leastone alternating current (AC) adapter. In a preferred embodiment, the atleast one AC adapter has an AC plug on a first end and a circularconnector (e.g., male FISCHER® 105 A087 connector) on a second end. Allof the at least two access ports, the at least two leads, or the atleast one access port and the at least one lead can be used to chargethe portable power case using AC adapters. In one embodiment, theportable power case has four access ports and can be charged in 16 hoursusing one AC adapter, 8 hours using two AC adapters, and 4 hours usingfour AC adapters.

In a preferred embodiment, the at least one AC adapter accepts a100-240VAC input and has a DC output of 17.4V. In one embodiment, the atleast one AC adapter has an indicator for the charge state (e.g.,red/orange indicates charging and green indicates charged).

The portable power case is operable to be charged using at least onesolar panel. In a preferred embodiment, the at least one solar panel isa combination signal marker panel and solar panel, such as thatdisclosed in US Publication Nos. 20170109978 and 20150200318, each ofwhich is incorporated herein by reference in its entirety.

In a preferred embodiment, the solar cells are formed of microsystemenabled photovoltaic (MEPV) material, such as that disclosed in U.S.Pat. Nos. 8,736,108, 9,029,681, 9,093,586, 9,143,053, 9,141,413,9,496,448, 9,508,881, 9,531,322, 9,548,411, and 9,559,219 and USPublication Nos. 20150114444 and 20150114451, each of which isincorporated herein by reference in its entirety.

In another preferred embodiment, the solar panel 2106 is made of glassfree, flexible thin film solar modules, such as those sold by FlexopowerUSA (Raleigh, N.C.). The solar modules are formed of amorphous siliconwith triple junction cell architecture. These solar modules continue todeliver power when damaged or perforated. Additionally, these panelsprovide higher production and a higher output in overcast conditionsthan comparable glass panels. These panels also provide betterperformance at a non-ideal angle of incidence.

FIG. 35 illustrates a portion of a combination signal marker panel andsolar panel 3300 made with glass free, thin film solar modules. Thecombination signal marker panel and solar panel 3300 includes aplurality, e.g., one or more, of solar modules 3301 mounted on aflexible substrate 3334. While FIG. 35 shows eighteen solar modules 3301in the solar panel 2106, this is exemplary only. The solar panel 2106can include any number of solar modules 3301 configured in series,configured in parallel, or configured in any combination of series andparallel arrangements. In particular, the configuration of solar modules3301 in the solar panel 2106 can be tailored in any way to provide acertain output voltage and current. The output of any arrangement ofsolar modules 3301 in the solar panel 2106 is a direct current (DC)voltage. Accordingly, the solar panel 2106 includes at least one outputconnector 3326 that is electrically connected to the arrangement ofsolar modules 3301 via a cable 3328. The at least one output connector3326 is used for connecting any type of DC load to the solar panel 2106.In one embodiment, the cable 3328 of the at least one output connector3326 includes a blocking diode to prevent power from running back intothe solar panel. In a preferred embodiment, the at least one outputconnector 3326 is a circular connector (e.g., male FISCHER® 105 A087connector).

In one embodiment, the at least one connector includes one or moreconnectors that allow a first solar panel to connect to a second solarpanel in series or in parallel. This allows a plurality of solar panels2106 of multiple combination signal marker panel and solar panels 3300to be connected together in series, in parallel, or any combination ofseries and parallel arrangements.

In a preferred embodiment, the solar panel 2106 includes eighteen solarmodules 3301. The maximum power is about 118W in one embodiment. Thevoltage at maximum power is about 28.8V in one embodiment. The currentat maximum power is about 4.1A in one embodiment.

The dimensions of the combination signal marker panel and solar panel3300 are about 8 feet by about 3 feet when deployed in one embodiment.The weight of the combination signal marker panel and solar panel 3300is preferably less than about 10 pounds. The combination signal markerpanel and solar panel 3300 weighs about 9 pounds in one embodiment.

The combination signal marker panel and solar panel 3300 is preferablyfoldable. Prior art solar panels that are rollable require a tube toroll the solar panel. The combination signal marker panel and solarpanel 3300 of the present invention does not require a tube, whichprovides a weight and volume savings advantage over prior art. Theweight and dimensions of the combination signal marker panel areimportant because it must be easily transported by a human. Soldiersoften carry 60-100 lbs. of gear, including equipment (e.g., radios,solar panels, batteries) in their rucksack or attached to their vest.Additional weight slows soldiers down and also makes it more likely thatthey will suffer injuries to their body (e.g., injuries to the back,shoulders, hips, knees, ankles, and feet). Additional volume alsoimpedes the movement of the soldiers.

The combination signal marker panel and solar panel 3300 includes clips(female clip 3352 shown) to secure the combination signal marker paneland solar panel 3300 when not in use in one embodiment. The solar panel2106 includes eyelets 3310, which allows the solar panel to be securedto the ground or another surface. While FIG. 35 shows a total of foureyelets 3310 (one in each corner), this is exemplary only. The solarpanel 2106 can include any number of eyelets 3310. The combinationsignal marker panel and solar panel 3300 has a vertical fold axis 3312,a top horizontal fold axis 3318, and a plurality of horizontal fold axes3314.

FIG. 36 shows a front perspective view of the combination signal markerpanel and solar panel 3300 while folded. The combination signal markerpanel and solar panel 3300 includes a handle 3350. The combinationsignal marker panel and solar panel 3300 also includes clips 3302 tosecure the combination signal marker panel and solar panel 3300 when notin use in one embodiment. The clips 3302 are attached to a front flap3336 via webbing 3354. The clips are attached at the other end towebbing 3356. The front flap 3336 partially covers a back side of theflexible substrate 3334 in one embodiment. The bottom webbing 3356 is intwo pieces that are secured by hook-and-loop tape in one embodiment.

FIG. 37 shows a back perspective view of one embodiment of thecombination signal marker panel and solar panel 3300 while folded. Thecombination signal marker panel and solar panel 3300 includes anintegrated pocket 3304 for holding the signal marker panel 3600 (notshown) when the solar panel 2106 is in use while the signal marker panel3600 is not in use. The integrated pocket 3304 can also be used to storethe at least one output connector 3326 (not shown) when not in use. Theintegrated pocket 3304 has an opening 3360. The opening 3360 of theintegrated pocket 3304 is preferably closed using a hook-and-loopfastener system. Alternatively, the opening 3360 of the integratedpocket 3304 is closed using ties, an arrangement of buttons or snaps, ora zipper.

FIG. 38 illustrates a top perspective view of one embodiment of thecombination signal marker panel and solar panel 3300 while unfolded. Thefront flap 3336 is connected to the female clips 3352 via webbing 3354.The front flap 3336 is connected to a top section 3340. The handle 3350is attached to the top section 3340. The top section 3340 is alsoconnected to the back flap 3338. The back flap 3338 contains theintegrated pocket 3304 (not shown). In a preferred embodiment, theintegrated pocket 3304 is on the reverse side of the back flap 3338 suchthat the integrated pocket is not exterior facing when the combinationsignal marker panel and solar panel 3300 is folded. This protects thecontents of the integrated pocket 3304 from accidentally spilling out.This also protects the cable 3328 from getting caught on other gear,vehicle components, etc. The back flap 3338 is also connected to themale clips 3358 via webbing 3356.

FIG. 39 illustrates another portion of a combination signal marker andsolar panel 3300. The cable 3328 is electrically connected to theplurality of solar modules 3301 (not shown) via a junction box 3370. Theat least one output connector 3326 (not shown) is secured in theintegrated pocket 3304.

In the embodiment shown in FIG. 39, the flexible substrate 3334 is shownin a camouflage pattern. Alternatively, the flexible substrate is asolid color (e.g., black, blue, brown, tan, green, white). In apreferred embodiment, the front flap, the top section, and the back flapare made of a canvas or nylon material. The front flap, the top section,and the back flap are formed of a camouflage pattern or a solid color(e.g., black, blue, brown, tan, green, white).

Representative camouflages include, but are not limited to, universalcamouflage pattern (UCP), also known as ACUPAT or ARPAT or Army CombatUniform; MultiCam, also known as Operation Enduring Freedom CamouflagePattern (OCP); Universal Camouflage Patter-Delta (UCP-Delta); AirmanBattle Uniform (ABU); Navy Working Uniform (NWU), including variants,such as, blue-grey, desert (Type II), and woodland (Type III); MARPAT,also known as Marine Corps Combat Utility Uniform, including woodland,desert, and winter/snow variants; Disruptive Overwhite Snow digitalcamouflage, and Tactical Assault Camouflage (TACAM).

Additionally, the combination signal marker panel and solar panel 3300includes features that allow the combination signal marker panel andsolar panel 3300 to be wearable in one embodiment. The combinationsignal marker panel and solar panel 3300 is be MOLLE-compatible inanother embodiment. “MOLLE” means Modular Lightweight Load-carryingEquipment, which is the current generation of load-bearing equipment andbackpacks utilized by a number of NATO armed forces. In one embodiment,the combination signal marker panel and solar panel 3300 incorporates apouch attachment ladder system (PALS), which is a grid of webbing usedto attach smaller equipment onto load-bearing platforms, such as vests,backpacks, and body armor. The pouch attachment ladder system is formedof a plurality of straps, a plurality of horizontal rows of webbing, aplurality of slits, and combinations thereof. For example, the PALS gridconsists of horizontal rows of 1-inch (2.5 cm) webbing, spaced about oneinch apart, and reattached to the backing at 1.5-inch (3.8 cm)intervals.

FIG. 40 illustrates one embodiment of a signal marker panel 3600. Thesignal marker panel is preferably rectangular or square in shape. In apreferred embodiment, the signal marker panel is fluorescent orange (or“international orange”) on a first side and cerise on a second side. Ina preferred embodiment, the signal marker panel is formed of ripstopnylon. The signal marker panel 3600 includes tie straps 3602, whichallows the signal marker panel 3600 to attach to different surfaces(e.g., the ground, trees, a backpack). In one embodiment, the tie straps3602 are made out of the same material as the signal marker panel 3600,nylon, elastic, hook-and-loop tape, or parachute cord. In oneembodiment, the signal marker panel 3600 includes snaps, which allowsmultiple signal marker panels 3600 to be connected together. The snapsinclude sockets 3604 (cap shown) and studs 3606.

FIG. 41 illustrates another embodiment of a signal marker panel 3600.The signal marker panel 3600 includes grommets 3608 on two opposingends. The signal marker panel 3600 also includes hook tape 3610 and looptape 3612 on both sides of the signal marker panel (i.e., on both thecerise and international orange sides). In an alternative embodiment,the signal marker panel includes hook tape 3610 and loop tape 3612 ononly one side. The signal marker panel includes hook tape 3610 and/orloop tape 3612 on two opposing ends of at least one side of the signalmarker panel in another embodiment. In one embodiment, the signal markerpanel is about 3 feet wide and about 3 feet long.

The portable power case is operable to be charged using at least onenon-rechargeable battery (e.g., BA-5590). Non-rechargeable batteries areoften used for military operations. The non-rechargeable batteries areoften discarded when 20-40% full to ensure that power is not lost whenon the battlefield. Advantageously, the portable power case can becharged using the remaining charge on non-rechargeable batteries,resulting in less wasted energy.

The portable power case is also operable to be charged using at leastone generator (e.g., NATO generators) or a fuel cell. In one embodiment,the fuel cell includes a metal-organic framework compound.

As previously described, the portable power case is operable to supplypower to a wearable battery. The wearable battery 2108 is preferably thebattery shown in FIG. 12B, wherein the battery is lined with a firstlayer of the heat-shielding or blocking and/or heat-dissipating materialand a second layer of the heat-shielding or blocking and/orheat-dissipating material, e.g., in a layer or lining, or coatingapplication.

In an alternate embodiment, the wearable battery 2108 is a portablebattery pack such as that disclosed in US Publication No. 20160118634 orU.S. application Ser. No. 15/720,270, each of which is incorporatedherein by reference in its entirety.

The portable power case is also operable to supply power to a laserdesignator and/or rangefinder. In a preferred embodiment, the laserdesignator and/or rangefinder is a Special Operations Forces LaserRangefinder Designator (SOFLAM). Alternative laser designators and/orrangefinders are compatible with the present invention.

The portable power case is also operable to supply power to acommunications system. In a preferred embodiment, the communicationssystem is the VIASAT® Move Out/Jump Off Kit (MOJO). The MOJO providessimultaneous line-of-sight and/or satellite communications for at leasttwo channels. The MOJO requires a one-step process for turning the MOJOon or off using DC power, such as when using the portable power case.The MOJO requires a four-step process for turning the MOJO on or offusing AC power. Further, the four steps must be completed in a specificorder. Advantageously, the portable power case allows for the one-stepprocess, which allows an operator to easily turn the MOJO on and off.Alternative communications systems are compatible with the presentinvention.

In one embodiment, the portable power case is operable to resuscitate avehicle battery if the vehicle battery dies using a contingency cable.One example of a vehicle used by the military is a POLARIS® MRZR®. Thereare two versions of the MRZR®: diesel and gasoline. The diesel versionhas two 12V lead acid batteries for a 24V output and an on-boardalternator. The gasoline version has a 12V lead acid battery, but doesnot have an on-board alternator. The lack of an on-board alternatormakes it more likely that the battery on the gasoline version will nolonger have sufficient charge to power the vehicle (i.e., the batterydies), leaving the passengers and the vehicle stranded. The contingencycable is a DC-DC converter cable with a dedicated hard-wired malecigarette lighter plug connector and a 12V output. Alternatively, thecontingency cable is connected to the vehicle battery using ringterminals, alligator clips, or a NATO slave adapter. The contingencycable is a DC-DC converter cable with a 12V or 24V output with adesulfating setting.

The portable power case is operable to connect to a power inverter. Thepower inverter changes direct current (DC) to alternating current (AC).This allows the portable power case to supply power to AC devices. Theportable power case supplies power to the power inverter through a DCinput cable. In a preferred embodiment, the DC input cable has one endwith a circular connector (e.g., male FISCHER® 105 A087 connector). Inan alternative embodiment, the portable power case includes a built-inpower inverter.

The portable power case is operable to supply power to a fish finderand/or a chartplotter, an aerator or a live bait well, a camera (e.g.,an underwater camera), a temperature and/or a depth sensor, a stereo, aradio, a drone, and/or a lighting system. In one embodiment, thelighting system includes at least one LED.

The above-mentioned examples are provided to serve the purpose ofclarifying the aspects of the invention, and it will be apparent to oneskilled in the art that they do not serve to limit the scope of theinvention. By way of example, the keyway may force the cable at an angleother than 30.0°. Voltages of batteries may be different.

The above-mentioned examples are just some of the many configurationsthat the mentioned components can take on. All modifications andimprovements have been deleted herein for the sake of conciseness andreadability but are properly within the scope of the present invention.

The invention claimed is:
 1. A portable power case comprising: a hardcase; a printed circuit board (PCB); at least two leads or at least oneaccess port and at least one lead connected to the PCB; at least oneuniversal serial bus (USB) port connected to the PCB; and at least onebattery removably connected to the PCB; wherein the hard case comprisesa lid and a base that form a housing having an interior surface, anexterior surface, and an open interior space; wherein the interiorsurface of the hard case is lined with a material that is resistant toheat; wherein the at least two leads or the at least one access port andthe at least one lead and the at least one USB port are accessiblypositioned on the exterior surface of the hard case; wherein the PCB andthe at least one battery are disposed within the open interior space ofthe hard case; wherein the at least one USB port, the at least twoleads, or the at least one access port and the at least one lead areoperable to supply power to at least one electronic device; wherein theat least two leads or the at least one access port and the at least onelead are operable to charge the portable power case using at least onecharging device; wherein the at least two leads or the at least one leadincludes a connector portion and a wiring portion; wherein a flexiblespring is provided around the wiring portion; and wherein the wiringportion and the flexible spring are held securely in the portable powercase such that a portion of the flexible spring is positioned outsidethe portable power case and another portion of the flexible spring ispositioned inside the portable power case forming a flexibleomnidirectional lead.
 2. The portable power case of claim 1, wherein theinterior surface of the hard case is lined with foam, a material that isresistant to electromagnetic interference, and/or a material that isresistant to radio frequency interference.
 3. The portable power case ofclaim 1, wherein the at least one charging device is a solar panel, analternating current (AC) adapter, a vehicle battery, a generator, and/ora non-rechargeable battery.
 4. The portable power case of claim 1,wherein the at least one electronic device is a radio, an amplifier, awearable battery, a mobile phone, a tablet, a smartphone, a camera, aglobal positioning system (GPS) device, a laser designator, arangefinder, a communications system, a thermal imaging device, a watch,a rechargeable battery, a satellite phone, a fish finder, achartplotter, an aerator, a live bait well, a temperature sensor, adepth sensor, a stereo, a drone, and/or a lighting system.
 5. Theportable power case of claim 1, wherein the connector portion has aningress protection (IP) rating of IPX6, IPX7, or IPX8.
 6. The portablepower case of claim 1, wherein the at least one access port includes akeyway.
 7. The portable power case of claim 1, wherein the flexiblespring is a helical shape.
 8. The portable power case of claim 1,wherein the at least one battery includes a lid and a plurality ofelectrochemical cells, and wherein the at least one battery includes aheat-resistant material functionally positioned between the lid and theplurality of electrochemical cells.
 9. The portable power case of claim1, wherein the at least one battery includes at least one latch, whereinthe at least one latch is operable to attach the at least one battery toa corresponding catch of a military radio.
 10. The portable power caseof claim 1, wherein the at least one battery is rechargeable, andwherein the at least one battery is selectively removable from the hardcase.
 11. The portable power case of claim 1, wherein the at least twoleads include a first lead and a second lead, and wherein the first leadand the second lead are staggered vertically and horizontally.
 12. Theportable power case of claim 1, wherein the hard case includes a firstgasket and a second gasket, wherein the first gasket and the secondgasket are positioned around each of the at least two leads, wherein thefirst gasket is positioned on the interior of the hard case, and whereinthe second gasket is positioned on the exterior of the hard case.
 13. Aportable power case comprising: a hard case; a printed circuit board(PCB); at least two leads or at least one access port and at least onelead connected to the PCB; and at least one battery removably connectedto the PCB; wherein the hard case comprises a lid and a base that form ahousing having an interior surface, an exterior surface, and an openinterior space; wherein the at least two leads or the at least oneaccess port and the at least one lead are accessibly positioned on theexterior surface of the hard case; wherein the PCB and the at least onebattery are disposed within the open interior space of the hard case;wherein the at least one battery is rechargeable; wherein the at leastone battery is selectively removable from the hard case; wherein the atleast two leads or the at least one access port and the at least onelead are operable to supply power to at least one electronic device;wherein the at least two leads or the at least one access port and theat least one lead are operable to charge the portable power case usingat least one charging device; wherein one of the at least one chargingdevice is a vehicle battery; wherein the portable power case isconnected to the vehicle battery through a cable with a batteryprotector; wherein the at least two leads or the at least one leadincludes a connector portion and a wiring portion; wherein a flexiblespring is provided around the wiring portion; and wherein the wiringportion and the flexible spring are held securely in the portable powercase such that a portion of the flexible spring is positioned outsidethe portable power case and another portion of the flexible spring ispositioned inside the portable power case forming a flexibleomnidirectional lead.
 14. The portable power of claim 13, wherein thebattery protector prevents the portable power case from draining thevehicle battery.
 15. The portable power case of claim 13, wherein thebattery protector is a timer or a low voltage disconnect.
 16. Theportable power case of claim 13, wherein the battery protector isconnected to the vehicle battery using ring terminals, alligator clips,or a North Atlantic Treaty Organization (NATO) slave adapter.
 17. Aportable power case comprising: a hard case; a printed circuit board(PCB); at least two leads or at least one access port and at least onelead connected to the PCB; and at least one battery removably connectedto the PCB; wherein the hard case comprises a lid and a base that form ahousing having an interior surface, an exterior surface, and an openinterior space; wherein the interior surface of the hard case is linedwith a material that is resistant to heat; wherein the at least twoleads or the at least one access port and the at least one lead areaccessibly positioned on the exterior surface of the hard case; whereinthe PCB and the at least one battery are disposed within the openinterior space of the hard case; wherein the at least two leads or theat least one access port and the at least one lead are operable tosupply power to at least one electronic device; wherein the at least twoleads or the at least one access port and the at least one lead areoperable to charge the portable power case using at least one chargingdevice; wherein the PCB includes control electronics configured todetermine a state of charge of the portable power case and/or the atleast one electronic device; wherein the at least two leads or the atleast one lead includes a connector portion and a wiring portion;wherein a flexible spring is provided around the wiring portion; andwherein the wiring portion and the flexible spring are held securely inthe portable power case such that a portion of the flexible spring ispositioned outside the portable power case and another portion of theflexible spring is positioned inside the portable power case forming aflexible omnidirectional lead.
 18. The portable power case of claim 17,wherein the exterior surface of the hard case includes at least oneindicator for indicating the state of charge, and wherein the at leastone indicator includes a visual mechanism, an auditory mechanism and/ora vibration mechanism.
 19. The portable power case of claim 17, whereinthe control electronics include a communications interface configured tocommunicate information related to the state of charge to a network. 20.The portable power case of claim 17, wherein the control electronicsinclude at least one processor, and wherein one or more of the at leastone processor is programmed to periodically measure the state of chargeand send state of charge information to at least one remote device.